Chevrolet - Astro Van Awd - Workshop Manual - 2018 - 2018

Factory Workshop Manual Make Chevrolet Model Astro Van 2wd Engine and year V6-4.3L VIN X (2002) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 16 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 17 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 38 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 39 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 42 Accessory Delay Module: Reading and Clearing Diagnostic Trouble Codes With Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. With Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 43 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 44 Steps 1-10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 45 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 46 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the pan number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software pan number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 47 Scan Tool Data List Scan Tool Output Controls Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 56 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 61 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 66 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 67 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 73 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 90 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 95 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 96 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 118 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 119 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 120 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 126 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 127 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 128 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 133 Door Lock Relay Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EBCM to BPMV 39 inch lbs. Front Brake Lines to BPMV 18 ft. lbs. Rear Brake Line to BPMV 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 138 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 139 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 140 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 141 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the 4 T-25 Tort mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 142 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 new T-25 Torx screws (1) in the EBCM (2). ^ Tighten the 4 T-25 Torx screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS on. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module (CCM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 147 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the cruise control cable. 2. Disconnect the electrical connector. 3. Remove the cruise control module bolts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module bolts. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable. 5. Perform the functional check. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on the M/L van is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). NOTE: Refer to Fastener Notice 2. Install the screws to the blower motor resistor assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 155 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Service and Repair Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the left side of the knee bolster. 2. Remove the cover (4) from the block to expose the DRL daytime running lights relay. 3. Remove the relay from the block. INSTALLATION PROCEDURE 1. Install the relay to the block. 2. Install the cover (4) to the block for the DRL daytime running lights relay. 3. Install the left side of the knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Convenience Center (Front View) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 176 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 181 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 182 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 183 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 184 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 185 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 186 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 188 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 189 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 190 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 191 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 192 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 193 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 194 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 196 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 197 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 198 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 199 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 200 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 201 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 202 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 211 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 212 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 215 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 216 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 217 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 218 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 219 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 226 Body Control Module C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 227 Body Control Module C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 228 Body Control Module: Description and Operation The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 231 Body Control Module: Removal and Replacement REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control. Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 232 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 233 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: ^ The Techline Terminal ^ The Scan Tool 9. Perform the body control module programing. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 238 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 239 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 279 Engine Control Module: Description and Operation Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 280 Engine Control Module: Description and Operation Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 281 Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 282 Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 283 Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed, with a brief description of the diagnostic functionality. Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the heated sensors are installed before and after the 3-Way Catalyst (TWC). Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 degrees hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor ( HO2S). A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The (TWC) and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx), the system uses a 3-way catalytic converter. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst heated oxygen sensors. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the 3-way catalytic converter. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 284 Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000 - 3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions. Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the effect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1 - 8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1 - 8. indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 285 sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 - Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential firing order are both misfiring, the first misfiring cylinder will accumulate misfires in its buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to it in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles, knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Three-Way Catalyst Oxygen Storage Capacity Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 286 Three-Way Catalyst Storage Capacity The PCM must monitor the 3-Way Catalyst System (TWC) for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor shows significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during its normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor voltage levels. Misfire Monitor Diagnostic Tests Whenever the sensor activity of the post-catalyst (2) oxygen sensor nears the sensor activity of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original pan, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) sensor ^ The Intake Air Temperature (IAT) sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load (6.0L only) ^ When one set of drive axles loses traction while the other set of drive axles are not moving (4WD only and in 4WD low) ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 287 cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. It controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed Sensor (VSS) ^ Mass Air Flow (MAF) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Crankshaft Position (CKP) Sensor ^ Knock Sensor (KS) ^ Throttle Position (TP) Sensor ^ Engine Coolant Temperature (ECT) Sensor ^ Camshaft Position (CMP) Sensor ^ Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable Closed Loop fuel control. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 288 Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) motor ^ The EVAP system ^ The electronic transmission controls ^ The A/C relay, if so equipped ^ The Vehicle Speed Sensor (VSS) output ^ The Malfunction Indicator Lamp (MIL) control ^ The cruise control enable, if so equipped Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information Engine Control Module: Service and Repair Additional Information The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 291 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 292 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the electronic control unit (ECU) location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 293 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL system. ^ HVAC systems ^ Engine cooling fans etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the DLC. 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal - This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI) - This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure - This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 294 connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ The Crankshaft Variation Learn Procedure ^ The Engine Oil Life Reset Procedure ^ The Idle Learn Procedure ^ The Inspection/Maintenance Complete System Set Procedure ^ The Vehicle Theft Deterrent Password Learn Procedure ^ The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. You must program the replacement control module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 295 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: ^ To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed. Removal Procedure NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 1. Disconnect the PCM harness connectors (4). 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 296 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (4) to the PCM (1). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 297 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 298 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 310 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 311 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 312 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 313 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 314 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 315 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 316 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 318 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 319 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 320 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 321 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 322 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 323 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 324 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 326 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 327 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 328 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 329 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 330 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 331 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 334 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 341 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 342 Ignition Control Module (ICM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 343 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS The ICM is connected to the PCM by an Ignition Control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 344 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 349 Inflatable Restraint Sensing And Diagnostic Module (SDM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 350 Air Bag Control Module: Service Precautions CAUTION: ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than Intended. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 351 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 352 Air Bag Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 353 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 354 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 355 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams Power Window Control Module: Diagrams Rear Window Wiper/Washer Module Windshield Wiper Motor And Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 374 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver Door Lock Switch - Front Passenger Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 388 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw at the front edge of the accessory switch mount plate. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 389 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 393 Seat Adjuster Switch - Driver Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 394 Power Seat Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 395 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 396 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 406 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 412 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 413 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 414 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 415 Wheel Speed Sensor: Diagrams Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 416 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD) Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the brake caliper (1). 4. Remove the hub and rotor assembly (3). 5. Remove the wheel speed sensor cable electrical connector (2). 6. Remove the wheel speed sensor harness clip rivets using a 3/16 inch drill bit. 7. Remove the clips from the wheel speed sensor wire. Save the clips for the replacement sensor. 8. Remove the wheel speed sensor mounting bolts and nut. 9. Remove the 2 splash shield mounting bolts (7). 10. Remove the wheel speed sensor and the splash shield assembly (6). 11. Remove the splash shield gasket. 12. Clean the gasket and knuckle (8) surfaces thoroughly with a dry cloth. Installation Procedure 1. Install the splash shield gasket. 2. Install the wheel speed sensor splash shield (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). 4. Install the wheel speed sensor mounting bolts and nut. ^ Tighten the speed sensor mounting bolts to 26 Nm (19 ft. lbs.). 5. Install the harness clips to the wheel speed sensor wire. Locate the clips at the paint dots on the wire. 6. Install the harness clips with 3/16 inch rivets. 7. Connect the wheel speed sensor electrical connector (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 417 8. Install the hub and rotor (3). 9. Install the brake caliper (1). 10. Install the tire and wheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 423 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 424 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 425 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 426 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 438 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 439 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Air Temperature Sensor Resistance Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 444 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 445 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 449 Blower Motor Switch: Diagrams Blower Motor Switch - A/C Auxiliary - HVAC Systems - Manual Blower Motor Switch - Heater Auxiliary Part 1 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 450 Blower Motor Switch - Heater Auxiliary Part 2 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary Air Conditioning REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 453 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 454 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 455 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 460 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED ^ J 5403 Snap Ring Pliers ^ J 9553-01 O-Ring Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. Refer to Refrigerant Recovery and Recharging. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 461 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 465 A/C Low Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 466 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (2) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch (1) to the accumulator (3). Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Headlamp And Panel Dimmer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Front > Page 475 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications Fuel Level Specifications The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 479 Fuel Pump And Sender Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 480 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 481 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 491 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 494 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 495 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 496 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 497 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 498 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 499 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 500 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 501 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 502 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 503 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 504 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 505 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 506 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 507 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 508 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 509 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 510 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 511 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 512 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 513 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 514 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 518 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Ambient Light Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 521 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 522 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 526 Stop Lamp Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 527 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 528 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Front > Page 536 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 545 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 546 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 547 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 548 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 549 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 550 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 551 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 552 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 553 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 554 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 555 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 556 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 557 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 558 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 559 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 560 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: Recalls Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 570 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 571 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 572 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 573 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 574 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 575 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 576 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 577 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 578 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 579 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 580 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 581 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 582 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 583 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 584 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 585 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: All Technical Service Bulletins Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 593 Headlamp Switch: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 605 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 606 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 608 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 609 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 610 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 611 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 612 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 613 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 614 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 615 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 617 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 618 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 619 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 620 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 621 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 622 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 623 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 624 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 625 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 626 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 627 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 628 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 629 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 630 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 631 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 636 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 637 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 638 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 639 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 645 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 646 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 649 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 650 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 651 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 652 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 653 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 654 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 655 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 656 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 658 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 659 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 660 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 661 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 662 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 663 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 664 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 665 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 666 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 667 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 668 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 669 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 670 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 671 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 672 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 675 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 676 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 677 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 678 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 679 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 680 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 681 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 682 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 683 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 684 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 685 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 689 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 690 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 691 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 692 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 701 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set > Page 707 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 708 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 717 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 719 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 720 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 721 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 722 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 724 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 725 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 726 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 727 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 728 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 729 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 730 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 737 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 740 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 743 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 744 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 747 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 748 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 749 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 750 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 751 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 755 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 759 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) Sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1 - 4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 760 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 761 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 765 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 766 Intake Air Temperature Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 767 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 768 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 776 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 783 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 784 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 799 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 800 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 801 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 803 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 804 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 806 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 807 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 808 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 812 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 813 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 814 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 815 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 816 1. Install the new MAP sensor grommet on the MAP sensor. 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 820 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 821 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 827 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 833 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 834 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 835 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 840 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 841 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 842 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors Oxygen Sensor: Description and Operation Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors > Page 862 Oxygen Sensor: Description and Operation Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 863 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 866 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 867 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 868 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (4) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 869 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 870 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5813695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (1) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 885 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 886 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 887 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 891 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 892 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 893 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 894 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 895 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 897 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 898 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 899 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 900 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 901 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 902 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 908 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 909 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 910 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 914 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 915 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 916 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 917 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 918 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 930 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 931 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 932 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 933 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 934 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 935 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 937 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 938 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 939 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 940 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 941 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 942 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 945 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 946 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 947 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Vehicle Speed Sensor (VSS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 964 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 967 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 968 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 969 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 970 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 971 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 972 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 973 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 975 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 976 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 977 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 978 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 979 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 980 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 981 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 982 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 983 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 984 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 985 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 986 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 987 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 988 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 989 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 991 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 993 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 994 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 995 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 996 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 997 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1015 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1016 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1017 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1018 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1019 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1020 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1021 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1022 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1023 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1024 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1025 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1026 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1027 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1028 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1029 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1030 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1031 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1035 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1036 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 1037 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1050 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1051 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1052 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1067 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1068 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1069 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1070 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1071 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1072 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1073 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1074 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1075 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1076 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1077 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1078 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1079 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1080 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1081 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1082 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1083 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1084 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 1093 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 1099 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1100 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1119 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1120 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1121 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1122 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1123 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1124 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1125 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1126 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1127 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1128 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1129 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1130 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1131 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1135 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1136 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1139 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1140 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1141 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1142 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1143 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1186 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1187 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1188 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1193 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1194 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1195 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1196 Impact Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Disconnect the mass air flow (MAF) and the intake air temperature (IAT) sensors harness connectors. 3. Loosen the clamp. 4. Remove the air tube from the throttle body air intake cover. 5. Remove the bolts. 6. Remove the upper radiator shroud. 7. Remove the fan and clutch assembly. 8. Remove the lower radiator shroud. 9. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the cradle (1). 10. Remove the bolts (2). 11. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the top of the cradle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 1199 Tighten Tighten fastener to 6.5 N.m (58 lb in). IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. 3. Perform the following steps in order to complete the first fastener repair; 3.1. Remove and discard the improperly installed rivet. 3.2. Reattach sensor with new rivet (GM P/N 15715058) or equivalent. 4. Perform the following steps, if needed, in order to complete a second fastener repair: 4.1. Remove the improperly installed rivet. 4.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 4.3. Insert and properly seat rivnut (GM P/N 15699834) or equivalent. 4.4. Install sensor with screw GM P/N 11515664, or equivalent. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 5. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 6. Install the lower radiator shroud. 7. Install the fan and clutch assembly. 8. Install the upper radiator shroud. 9. Install the air box with MAF sensor to the upper radiator shroud. 10. Connect the air tube to the throttle body air intake cover with the clamp. 11. Connect the MAF and IAT sensors harness connectors. 12. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 1200 Impact Sensor: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 1201 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 1202 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 1203 Impact Sensor: Service and Repair SIR Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of collision damage. The area of collision damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. ^ Replace the sensor even if the air bags have not deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1207 Seat Belt Buckle Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 1229 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1233 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1234 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1235 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1236 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1237 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1241 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1242 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 Power Window Switch: Connector Views Window Master Switch - Driver C1 Window Switch - Front Passenger C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 Window Master Switch - Driver C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 Window Switch - Front Passenger C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Rear Window Wiper Washer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1297 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1298 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1299 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1300 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1301 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1302 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1303 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Camber Service Allowed -0.40 to + 1.60 Service Preferred 0.6 Cross Camber (L-R) Service Allowed -0.5 to +0.5 Service Preferred 0 Caster-Left Wheel Service Allowed 2.0 to 4.0 Service Preferred 3.0 Caster-Right Wheel Service Allowed 2.50 to 4.50 Service Preferred 3.5 Cross Caster (L-R) Service Allowed -1 to 0 Service Preferred -0.5 Steering Wheel Angle Service Allowed -6.0 to +4.0 Service Preferred -1.0 Toe (Total) Service Allowed 0.20 to 0.20 Service Preferred 0 Z Trim Height Service Allowed 2.86 to 3.34 in Service Preferred 3.10 in D Trim Height Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 1306 Alignment: Specifications Z Trim Height RWD Service Allowed 2.86 to 3.34 in Service Preferred 3.10 in AWD Service Allowed 5.16 to 5.64 in Service Preferred 5.40 in D Trim Height ALL Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1307 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1308 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1309 causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 5. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1312 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: - Sagging front suspension. - Worn rear suspension components, such as leaf spring bushings. - Improper tire inflation. - Improper weight distribution. - Collision damage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1313 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1314 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and the camber adjustments are made by inserting shims between the upper control arm shaft and the frame bracket. The shims may be added, subtracted, or transferred in order to change the readings. Important: Before adjusting the caster and the camber angles, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - When checking the left and the right side caster and camber, it must be equal within 1.0 degree. - When setting the left and the right side caster and camber, it must be equal within 0.50 degree. - The caster and the camber set is relative to the ground. 1. Loosen the upper control arm shaft to frame nuts (1). Important: A normal shim pack will leave at least 24/~ threads of the bolt exposed beyond the nut. The maximum shim pack cannot be thicker than 21.3 mm (0.84 inch). - The difference between the front shim packs and the rear shim packs must not exceed 10 mm (0.40 inch). If these requirements cannot be met, check for damaged control arms and damaged related parts. 2. If the caster is not within specifications, adjust the caster by transferring the front shims to the rear, or the rear shims to the front. The transfer of the one shim from the rear bolt to the front bolt will decrease the positive caster. 3. If the camber is not within specification, adjust the camber by changing the shims at both the front and the rear of the shaft. Add or subtract the shims (2) as required. Adding an equal number of shims at both the front and rear of the cross shaft will decrease positive camber. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the nut on the thinner shim pack first. - Tighten the nuts to 110 Nm (81 ft. lbs.). Tightening the nut on the thinner shim pack first improves the shaft to frame clamping force and torque retention. 5. Check the toe-in after changing the caster or the camber. Front Wheel Toe Adjustment Front Toe Adjustment The toe-in can be increased or decreased by changing the length of the tie rods. A threaded sleeve is provided for this purpose. When the tie rods are mounted ahead of the steering knuckle, the tie rods must be modified as follows: Decreased in length in order to increase the toe-in. Increased in length in order to decrease the toe-in. Important: When checking and setting the toe-in, the left and right side to be set separately and the steering wheel must be held straight ahead position within 4 - 6 degrees. Before adjusting the toe-in, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Adjust the toe-in with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - For an accurate toe-in reading, do not push or pull on the tires during the alignment process. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 1315 1. Set the steering wheel in the straight ahead position. 2. Loosen the clamp bolts at each end of the steering tie rod adjustable sleeves. Important: The tie rod adjuster often becomes rusted in service. 3. If the torque needed to rotate the adjuster tube exceeds 9 Nm (80 inch lbs.), perform the following steps: 3.1. Remove the adjuster tube clamp nuts and the bolts. Discard the nuts and the bolts. 3.2. Apply the penetrating oil between the adjuster tube and the tie rod threads. 3.3. Rotate the adjuster tube until the tube moves freely. 3.4. Install the new bolts and the nuts with the correct part number. The nut must be towards the front of the vehicle. 4. Rotate the inner and the outer tie rod sockets rearward to the limit of the ball stud travel. 5. Turn the tie rod adjusting sleeves to set the toe-in to specifications. Notice: Refer to Fastener Notice in Service Precautions. Important: Before tightening the adjuster tube nuts, do the following: Check the number of threads on each tie rod within the adjuster tube. The tie rod threads within the adjuster tube must be equal to within 3 threads. - Check the relationship of the adjuster tube to the clamp. The adjuster tube slot and the clamp opening must not be in the same position. The position of the adjuster tube clamp must not exceed 30 degrees in either direction. - The adjuster tube clamp must be on the inside of the adjuster tube dimple. 6. Tighten the adjuster tube clamp nuts. - Tighten the adjuster tube clamp nuts to 25 Nm (18 ft. lbs.). The clamp ends may touch when the nuts are tightened to specification. 7. Rotate the tie rod sockets to the centered position. Ensure that the outer socket is square with the stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the Mass Air Flow/Intake Air Temperature ( MAF/IAT) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1336 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1342 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1343 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1349 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1350 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: ^ Tearing ^ Piercing ^ Arcing ^ Carbon tracking ^ Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 1355 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 1356 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1365 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1366 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1372 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 1373 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 4. Remove the 2 screws from the rotor. 5. Remove the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1376 6. Note the locating holes that the rotor was removed from: ^ The rotor screw holes (1) ^ The rotor locator pin holes (2) 7. Line up the square-cut hole in the vane wheel with the CMP sensor. 8. Remove the 2 screws that hold the camshaft position (CMP) sensor. 9. Discard the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1377 10. Remove the CMP sensor. 11. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Support the distributor drive gear in a V-block or similar fixture. 13. Drive out the roll pin with a suitable punch. 14. Remove the driven gear from the distributor shaft. 15. Remove the round washer. 16. Remove the tang washer. 17. Remove the shim washer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1378 18. Remove the old oil seal. ASSEMBLY PROCEDURE IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. 2. Insert the sensor into the housing. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1379 3. Install two new screws for the camshaft position (CMP) sensor. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identity the correct rotor mounting position: ^ At the rotor screw holes (1) ^ At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1380 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 14. Support the distributor drive gear in a V-block or similar fixture. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1381 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1382 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: ^ The intake manifold ^ The cylinder head ^ The camshaft ^ The timing chain or sprockets ^ The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. ^ Twist each spark plug 1/2 turn. ^ Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1383 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1384 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). ^ If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. ^ In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1385 NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1386 13. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 15. Install the engine cover. INSTALLATION PROCEDURE 2 IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1387 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). ^ The alignment will not be exact. ^ If the driven gear is installed incorrectly, the dimple Will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. 4. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1388 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1389 8. Install the distributor cap. 9. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 13. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 14. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 1390 Distributor: Service and Repair Distributor Inspection 1. Remove the engine cover. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Ignition System Specifications Spark Plug Torque 15 N.m Spark Plug Gap 1.52 mm Spark Plug Type R41-932 [AC plug type] Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1394 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................ R41-932 (AC plug type) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling - Colder plug ^ Pre-ignition causing spark plug and/or engine damage - Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 1397 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 1398 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 1399 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed Specification Spark plug gap: 1.524 mm (0.060 in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection Normal The compression builds up quickly and evenly to the specified compression. Leaking The compression is low on the first compression stroke. The compression builds up with the following strokes, but does not reach the specified compression. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1407 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1408 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1409 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1412 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1413 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1414 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1415 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belts) is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1416 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1417 procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1418 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1419 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belts) is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1420 Diagnostic Aids A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent verify the accessory drive components by varying their loads. Ensure the accessory components are operated to their maximum capacity. An overcharged A/C system or power steering system with: a pinched hose, an incorrect fluid, or a failed generator are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt or an accessory drive component. If the drive belt is removed, the water pump may not operate. Without the water pump the engine may overheat. DTCs may set when the engine is operating with the drive belt removed. 4. This test verifies that an accessory drive component does not have a seized bearing. Remove the belt and test the bearings for smooth turning in the accessory drive components. Test the accessory drive components with the engine operating, vary the load on the components to verify that the components operate correctly. 5. This test is to verify that the drive belt tensioner operates correctly. If the drive belt tensioner is not operating correctly, correct belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working correctly. Also if an incorrect length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a pulley that is incorrectly aligned using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1421 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1422 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. DTCs may set if the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the correct inspection and replacement procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1423 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the air cleaner outlet duct from the throttle body. 3. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 4. Remove the drive belt. 5. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the belt over all the pulleys except the tensioner arm. 2. Observe drive belt routing for vehicles without air conditioning. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1424 3. Observe drive belt routing for vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counter clockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1425 8. Avoid mix-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed, the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed, the fix pointer should not align past the index mark. 11. Install the air cleaner outlet duct. 12. Install the air cleaner assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the Mass Air Flow/Intake Air Temperature ( MAF/IAT) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1439 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1445 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1446 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1450 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1451 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1452 Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1458 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1459 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1463 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Note the position of the fuel strainer (2) on the fuel sender. 3. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 4. Pull the strainer off the fuel sender. Discard the strainer after inspection. 5. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement Oil Filter: Service and Repair Oil Filter Bypass Valve Replacement Oil Filter Bypass Valve Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter. 4. Remove the oil filter adapter. 5. Using a suitable prying tool remove the oil filter bypass valve. 6. Clean and inspect valve bore for damage. Installation Procedure Caution: Refer to Safety Glasses Caution in Service Precautions. 1. Install a NEW oil filter bypass valve using the following procedure: 1.1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. 1.2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 1.3. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart. 2. Install the oil filter adapter. 3. Install the oil filter. 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement > Page 1470 Oil Filter: Service and Repair Draining Fluids and Oil Filter Removal Draining Fluids and Oil Filter Removal 1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container. 2. Remove the oil filter (if applicable). 3. Discard the oil filter (if applicable). 4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container. Engine Flywheel Removal Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement > Page 1471 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port.. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1476 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1) tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1477 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1478 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1479 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1480 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1481 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The ruts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1482 7. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1483 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1484 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1485 7. Remove the A/C refrigerant filter (6) from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1486 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1487 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port.. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1488 IMPORTANT: DO NOT install the O-rings (2) in this step. 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1) tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1489 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1490 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1491 14. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1492 REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The ruts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1493 7. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1494 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1495 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1496 7. Remove the A/C refrigerant filter (6) from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1497 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Suction Screen Installation TOOL REQUIRED J 44551 Suction Screen Installation/ Removal Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-5 sizing tool into the suction hose to select the correct size suction screen. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 1498 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel to the J 44551-5. 4. Install the J 44551-5 screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. 6. Remove the J 44551-5 suction screen tool from the suction hose. IMPORTANT: After major compressor failure a A/C refrigerant filter should also be installed. 7. Install an A/C refrigerant filter. 8. Install the J 44551-1 Suction Screen Notification label. Suction Screen Replacement TOOLS REQUIRED ^ J 42220 Universal Leak Detection Lamp ^ J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the Engine cover. 3. Remove the A/C compressor hose assembly bolt. 4. Separate the A/C compressor hose assembly from the A/C compressor. IMPORTANT: The suction screens are available in 3 different sizes. 5. Select the proper size removal tool from the J 44551. 6. Remove the suction screen using the J 44551-31 suction screen removal tool. ^ Thread the forcing screw into the suction screen. ^ Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel to the J 44551-5. 4. Install the J 44551-5 suction screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the A/C compressor hose assembly bolt. Tighten Tighten the bolt to (25 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 42220. 12. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Oil Cooler Pipe Bracket Bolt to Oil Pan Torque ................................................................................................................................................. ............................................................ 89 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolts (3) that retain the front pipes (5) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1507 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1508 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1509 Heater Hose: Service and Repair Heater Hose Replacement - Inlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the inlet (3) hose from the heater core. 7. Disconnect the inlet (3) hose from the water valve. INSTALLATION PROCEDURE 1. Connect the inlet (3) hose to the water valve. 2. Connect the inlet (3) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1510 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fittings component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1511 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the outlet (2) hoses from the heater core. 7. Disconnect the outlet (2) hoses from the water valve. INSTALLATION PROCEDURE 1. Connect the outlet (2) hose to the water valve. 2. Connect the outlet (2) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 1512 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fitting component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Remove the compressor hose assembly bolt (2) from the compressor. 8. Remove the old sealing washers from the compressor. 9. Remove the hose clamp bracket nut (3) from the engine stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1517 10. Remove the compressor hose assembly nut (6) from the condenser. 11. Remove the compressor hose assembly nut (1) from the accumulator. 12. Remove the bolt from the transmission filler tube to the oil indicator tube. 13. Remove transmission filler tube from the throttle cable bracket. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections on the vehicle. INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolt to the transmission filler tube to the oil indicator tube. Tighten Tighten the bolt to the oil indicator tube to 12 N.m (106 lb in). 5. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1518 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the compressor hose assembly seals. 9. Install the sealing washers. 10. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). 11. Install the engine cover. 12. Install the grille. 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. 15. Install the air cleaner. 16. Connect the IAT sensor. 17. Connect the MAF sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1519 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1520 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1521 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1522 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Raise vehicle. Refer to Lifting and Jacking the Vehicle. 8. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 9. Lower vehicle. 10. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1523 11. Remove the hose clamp bracket nut (3) from the engine stud. 12. Remove the compressor hose assembly bolt from the compressor. 13. Remove the sealing washers from the compressor. 14. Remove the compressor hose assembly nut (6) from the condenser. 15. Remove the compressor hose assembly nut (1) from the accumulator. 16. Remove the compressor hose assembly from the vehicle. 17. Cap or plug all open connections. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1524 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the compressor hose assembly nut (1) to the accumulator to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the compressor hose assembly nut to the condenser to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1525 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1526 9. Raise the vehicle. 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. 17. Connect the IAT sensor. 18. Connect the MAF sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1527 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube (2) from the evaporator. 4. Remove the O-ring seal. 5. Remove the grille. 6. Remove the evaporator tube (2) from the condenser (4). 7. Remove the O-ring seal. 8. Remove the evaporator tube from the auxiliary A/C evaporator underbody front tube assembly (if equipped). INSTALLATION PROCEDURE 1. Install the NEW O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). NOTE: Refer to Fastener Notice in Caution and Notices. 3. Tighten the evaporator tube nut (3) to the condenser (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1528 Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Install the evaporator tube to the auxiliary A/C evaporator underbody front tube assembly (if equipped). Tighten Tighten the evaporator tube nut to the auxiliary A/C evaporator to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1529 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Remove the compressor hose assembly bolt (2) from the compressor. 8. Remove the old sealing washers from the compressor. 9. Remove the hose clamp bracket nut (3) from the engine stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1530 10. Remove the compressor hose assembly nut (6) from the condenser. 11. Remove the compressor hose assembly nut (1) from the accumulator. 12. Remove the bolt from the transmission filler tube to the oil indicator tube. 13. Remove transmission filler tube from the throttle cable bracket. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections on the vehicle. INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolt to the transmission filler tube to the oil indicator tube. Tighten Tighten the bolt to the oil indicator tube to 12 N.m (106 lb in). 5. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1531 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the compressor hose assembly seals. 9. Install the sealing washers. 10. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). 11. Install the engine cover. 12. Install the grille. 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. 15. Install the air cleaner. 16. Connect the IAT sensor. 17. Connect the MAF sensor. Accumulator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1532 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1533 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1534 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Compressor/Condenser Hose Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1535 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Raise vehicle. Refer to Lifting and Jacking the Vehicle. 8. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 9. Lower vehicle. 10. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1536 11. Remove the hose clamp bracket nut (3) from the engine stud. 12. Remove the compressor hose assembly bolt from the compressor. 13. Remove the sealing washers from the compressor. 14. Remove the compressor hose assembly nut (6) from the condenser. 15. Remove the compressor hose assembly nut (1) from the accumulator. 16. Remove the compressor hose assembly from the vehicle. 17. Cap or plug all open connections. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1537 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the compressor hose assembly nut (1) to the accumulator to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the compressor hose assembly nut to the condenser to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1538 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1539 9. Raise the vehicle. 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. 17. Connect the IAT sensor. 18. Connect the MAF sensor. Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube (2) from the evaporator. 4. Remove the O-ring seal. 5. Remove the grille. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1540 6. Remove the evaporator tube (2) from the condenser (4). 7. Remove the O-ring seal. 8. Remove the evaporator tube from the auxiliary A/C evaporator underbody front tube assembly (if equipped). INSTALLATION PROCEDURE 1. Install the NEW O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). NOTE: Refer to Fastener Notice in Caution and Notices. 3. Tighten the evaporator tube nut (3) to the condenser (4). Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Install the evaporator tube to the auxiliary A/C evaporator underbody front tube assembly (if equipped). Tighten Tighten the evaporator tube nut to the auxiliary A/C evaporator to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Evaporator Tube Replacement - Auxiliary Front TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1541 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator front inlet tube from the evaporator inlet tube (2) at the accumulator. 4. Remove the O-ring seal. 5. Remove the bolts (3) that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. 6. Remove the auxiliary evaporator front inlet tube (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator front inlet tube (2) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. 4. Install the auxiliary evaporator front inlet tube (2) to the auxiliary evaporator side inlet tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Lower the vehicle. 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1542 Evaporator Tube Replacement - Auxiliary Rear TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator rear outlet tube from the auxiliary evaporator outlet side tubes. 4. Remove the auxiliary evaporator rear inlet tube from the auxiliary evaporator inlet side tubes. 5. Remove the bolts that retain the clips on the tubes to the body. 6. Remove the nut that retains the tube to the auxiliary evaporator module. 7. Remove the tube from the auxiliary evaporator module. 8. Remove the seal washers INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1543 1. Install the seal washers. 2. Install the tube to the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Caution and Notices. 3. Install the nut that retains the tube to the auxiliary evaporator module. Tighten Tighten the nut to 25 N.m (18 lb ft). 4. Install the bolts that retain the clips on the tubes to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Install the auxiliary evaporator rear tube inlet tube to the auxiliary evaporator inlet side tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 6. Install the auxiliary evaporator rear tube outlet tube to the auxiliary evaporator outlet side tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1544 9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator rear tube (3). 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator front tube (2). 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1545 7. Remove the bolts (1) that retain the clips on the auxiliary side inlet tube (3) to the body. 8. Remove the auxiliary evaporator side inlet tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator side inlet tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts that retain the clips on the auxiliary evaporator side inlet tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 1546 4. Install the auxiliary evaporator side inlet tube to the auxiliary evaporator front inlet tube (2). Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 6. Install the auxiliary evaporator side inlet tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: Customer Interest Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 1555 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering Whistle Noise When Driving Straight Power Steering Line/Hose: All Technical Service Bulletins Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering Whistle Noise When Driving Straight > Page 1561 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1562 Power Steering Line/Hose: Specifications Power Steering Hose Fittings 20 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Disconnect the power steering cooler hose from the steering pump. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Install a drain pan under the vehicle. 4. Disconnect the power steering cooler pipe hose from the steering gear. 5. Remove the power steering cooler pipe (2) from the air baffle (3). 6. Remove the power steering cooler pipe from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1565 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe (2) to the air baffle (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the power steering cooler pipe to the steering gear. - Tighten the power steering cooler pipe to the steering gear to 27 Nm (20 ft. lbs.). 4. Lower the vehicle. 5. Connect the power steering cooler hose to the steering pump. 6. Bleed the power steering system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1566 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the hydraulic brake booster inlet hose from the of the power steering pump. 3. Lower the vehicle. 4. Disconnect the hydraulic brake booster inlet hose from the hydraulic brake booster. 5. Remove the hydraulic brake booster inlet hose from vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1567 1. Install the hydraulic brake booster inlet hose to vehicle. 2. Connect the hydraulic brake booster inlet hose to the hydraulic brake booster. 3. Raise the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the hydraulic brake booster inlet hose to the power steering pump. - Tighten the hydraulic brake booster inlet hose to the power steering pump to 27 Nm (20 ft. lbs.). 5. Bleed the system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1568 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Important: Note the position of all the tie-straps, power steering hoses and the hose insulators for proper re-installation. 1. Remove the power brake booster outlet hose tie-straps. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering gear. 4. Disconnect the hydraulic brake booster outlet hose from the steering gear. 5. Disconnect the hydraulic brake booster outlet hose from the hydraulic brake booster. 6. Remove the hydraulic brake booster outlet hose from the vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 1569 1. Install the hydraulic brake booster outlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the hydraulic brake booster outlet hose to the hydraulic brake booster. - Tighten the hydraulic brake booster outlet hose to the hydraulic brake booster to 27 Nm (20 ft. lbs.). 3. Connect the hydraulic brake booster outlet hose to the power steering gear. - Tighten the hydraulic brake booster outlet hose to the power steering gear to 27 Nm (20 ft. lbs.). 4. Remove the drain pan. 5. Install the hydraulic brake booster outlet hose tie straps. 6. Bleed the system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Specifications Radiator Hose: Specifications Upper Radiator Hose Support Bracket Nut to Exhaust Manifold Stud Torque ................................................................................................................................................. ................................................................ 27 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet Removal Procedure 1. Drain the coolant from the radiator to a level below the hose being removed. 2. Remove the air cleaner assembly. 3. Reposition the radiator hose clamp. 4. Remove the inlet hose from the radiator. 5. Reposition the clamp from the thermostat housing. 6. Remove the inlet hose from the thermostat housing Installation Procedure 1. Install the inlet hose to the thermostat housing. 2. Reposition the clamp to the thermostat housing. 3. Install the inlet hose to the radiator. 4. Reposition the clamp to the radiator. 5. Install the air cleaner assembly. 6. Fill the coolant to the proper level. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 1575 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet Removal Procedure 1. Drain the engine coolant. 2. Remove the air cleaner assembly. 3. Reposition the radiator hose clamp. 4. Remove the outlet hose from the radiator. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Reposition the outlet hose clamp from the water pump. 7. Remove the outlet hose from the water pump. Installation Procedure 1. Install the outlet hose to the water pump. 2. Reposition the outlet hose clamp to the water pump. 3. Lower the vehicle. Refer to Vehicle Lifting. 4. Install the outlet hose to radiator. 5. Reposition the radiator hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 1576 6. Install the air cleaner assembly. 7. Fill the engine coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Type Delco Supreme 11 or equivalent DOT-3 brake fluid Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1585 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1586 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1587 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1588 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity w/ C36 (Rear Heater) .......................................................................................................................... .................................................................. 16.5 qts. w/o C36 (Rear Heater) ....................................... ................................................................................................................................................... 13.5 qts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1591 Coolant: Fluid Type Specifications Coolant Type .................................................................................................... Use only GM Goodwrench(R) Dex-Cool(R) in a 50/50 mixture with clean water. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1596 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1597 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1598 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1599 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 4.7L (5.0 Qt) Overhaul ........................... .............................................................................................................................................................. ............... 10.6L (11.0 Qt) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1602 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1603 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1604 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1605 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1606 Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Differential Oil Capacity Capacity ............................................................................................................................................... .................................................................... 3.5 Pints Front Differential Differential Oil Capacity Front .................................................................................................................................................... .......................................................... 1.2L (2.6 Pints) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1611 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Front Grade ......................................................................................................................................... .................................................................................... GL-5 Viscosity ................................................ .............................................................................................................................................................. ..... 80W-90 Rear Grade ...................................................................................................................... ................................................................................................. Synthetic Viscosity ............................. .............................................................................................................................................................. ........................ 75W-90 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check Fluid - Differential: Service and Repair Lubricant Level Check Lubricant Level Check 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check > Page 1614 Fluid - Differential: Service and Repair Lubricant Change Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover and the rear axle housing cover gasket. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Install the new rear axle housing cover gasket and the rear axle housing cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check > Page 1615 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear axle housing cover bolts. Tighten the rear axle housing cover bolts to 30 Nm (22 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1620 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1621 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 4.2L (4.5 Qt) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1624 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Viscosity ........................................................... .......................................................................................................................................................... 5W-30 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1625 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1626 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering System GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1634 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1635 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.0 lb. (0.91 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1638 Refrigerant: Fluid Type Specifications Type R-134a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1639 Refrigerant: Service Precautions CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1640 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 43600 ACR 2000 Air Conditioning Service Center ^ J 45037 A/C Oil Injector CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant System Capacities - Heating, Ventilation And Air Conditioning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1647 Refrigerant Oil: Fluid Type Specifications PAG (Polyalkaline Glycol) synthetic refrigerant oil (GM part number 12345923) or equivalent. For Canada use GM P/N 10953486. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1648 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting (Leak Testing the Hydraulic Brake System) 10 psi Pressure Bleed Procedure Setting 35 psi Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two Person Procedure Important: ^ Use the 2-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to one full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid that is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1654 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM PIN 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 17.1. Inspect the brake system for external leaks. 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1655 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1656 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177 Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J 39177, or equivalent to the metering valve. 6. Using the J 39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J41613 to the J29567. 8. Install the J41618 and J29567to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J29532, or equivalent, to the J 29567. 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1657 valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J29567 from the brake master cylinder reservoir. 23. Remove the J 39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1658 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the halfway point with Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 1663 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - I/P Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - I/P > Page 1671 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1674 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1675 Fuse: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1676 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1677 Fuse: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1678 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1679 Fuse: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 1680 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block > Page 1685 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1686 Fuse Block: Diagrams Convenience Center C1 Convenience Center C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1687 Convenience Center C4 Convenience Center C5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1688 Convenience Center C6 Convenience Center C8 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1689 Convenience Center C9 Convenience Center C10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) Fuse Block: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1692 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1693 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1694 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1695 Fuse Block: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1696 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1697 Fuse Block: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 1698 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Fuse Block: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. IMPORTANT: ^ Always note the orientation of the relay. ^ Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 1701 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 1702 Fuse Block: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any Connector Position Assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any Connector Position Assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Relay Block #1 > Page 1707 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Relay Block #1 > Page 1708 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 1711 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 1712 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 1713 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 1714 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 1715 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The numbers below refer to the step numbers on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 1721 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 1722 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1730 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Vehicle Lifting Points 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1731 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: * Beneath the lower control arms, inboard from the shock absorber mounts * Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: * Beneath the axle housing, inboard from the shock absorber mounts * Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: * Chock the wheels at the end of the vehicle opposite the end being lifted * Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Jacking and Lifting Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: * The catalytic converter * The brake lines * The brake cables * The fuel lines * The accelerator cables * The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 1755 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Remove the spare tire from the tire carrier. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the pin and retainer from the shaft. 4. Remove the shaft from the hoist. 5. Remove the hoist mounting bolts. 6. Remove the hoist from the rear crossmember. Installation Procedure 1. Install the hoist to the rear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hoist mounting bolts and nuts. ^ Tighten the hoist mounting bolts and nuts to 15 Nm (11 ft. lbs.). 3. Install the shaft to the hoist. 4. Install the pin and retainer to the shaft. 5. Lower the vehicle. 6. Install the spare tire to the carrier. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1764 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1765 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1766 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1771 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1776 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1777 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1778 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1784 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1785 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1786 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1791 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1796 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1797 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1802 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1803 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1804 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1809 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1814 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1815 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1816 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1826 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1827 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1828 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1833 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1838 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1839 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1844 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 200 - 229 mm (09 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1845 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 1848 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrape ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) - Tools Required J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1854 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle - Classify the failure of the wheel bearing with the aid of the illustrations. - Determine the cause of the wheel bearing failure. - Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1855 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1856 Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1857 Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears The smearing of the metal is due to slippage. Slippage can be caused by the following factors: Poor fits - Lubrication - Overheating - Overloads - Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1858 Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1859 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 1860 Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1861 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 1862 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications wheel hub nut 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1875 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1881 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1882 Wheel Fastener: Specifications Wheel nuts 100 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Removal Procedure 1. Remove the rotor. 2. Remove the wheel stud. ^ Press the stud out using an arbor press. ^ Do not damage the wheel mounting surface on the wheel hub flange. Installation Procedure 1. Install the stud into the hole in the wheel hub. 1.1. Start the serrated stud into the hole in the wheel hub by tapping lightly with a hammer. 1.2. The stud must be square with the wheel hub before pressing on the arbor press. 2. Install the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1885 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J 43631. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1886 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 1887 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: ^ Always shield your eyes. ^ Avoid leaning over the battery whenever possible. ^ Do not expose the battery to open flames or sparks. ^ Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1891 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: ^ Always shield your eyes. ^ Avoid leaning over the battery whenever possible. ^ Do not expose the battery to open flames or sparks. ^ Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. ^ Do not let the 2 vehicles touch. ^ Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1892 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1896 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Vehicle Lifting Points 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1897 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: * Beneath the lower control arms, inboard from the shock absorber mounts * Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: * Beneath the axle housing, inboard from the shock absorber mounts * Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: * Chock the wheels at the end of the vehicle opposite the end being lifted * Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Jacking and Lifting Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: * The catalytic converter * The brake lines * The brake cables * The fuel lines * The accelerator cables * The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures Access Cover: Procedures Engine Cover ENGINE COVER Removal Procedure 1. Remove the instrument panel extension. Refer to "Instrument Panel Extension". 2. Remove the floor air outlet duct. Refer to "Air Outlet - Center Floor". 3. Remove the bolts from the brackets: ^ Loosen the bolt. ^ Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1904 6. Remove the engine cover. Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. 3. Install the latch screws. Tighten Tighten the latch screws to 4 Nm (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten Tighten the engine cove bolt to 25 Nm (18 lb ft). 5. Insert the floor air outlet duct. 6. Insert the instrument panel extension. Instrument Panel (IP) Extension INSTRUMENT PANEL (I/P) EXTENSION REPLACEMENT REMOVAL PROCEDURE 1. Remove the caps that cover the extension screws. 2. Remove the screws from the extension. 3. Remove the nuts at the bottom of the extension. 4. Pull toward the rear of the vehicle in order to remove the extension from the instrument panel. 5. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1905 2. Install the extension to the instrument panel: 2.1. Align the retainers. 2.2. Press the extension into place until the retainers are seated. 3. Install the nuts that retain the extension to the floor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts that retain the extension to the floor to 8 Nm (71 lb in). 4. Install the retaining screws. Tighten Tighten the screws to 8 Nm (71 lb in). 5. Install the extension screw covers. Air Outlet - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. Refer to "Instrument Panel (I/P) Extension". 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. Refer to "Seat Replacement Bucket". 4. Remove the front section of the carpet, if equipped. Refer to "MAT/Carpet Replacement". Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1906 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1907 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 Nm (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Engine Cover Guide Assembly ENGINE COVER GUIDE ASSEMBLY Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement. 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly from the vehicle. Installation Procedure 1. Install the engine cover guide assembly. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten Tighten the bolts that retain the engine cover guide to 8.5 Nm (75 lb in). 3. Install the engine cover. MAT/Carpet Replacement MAT/CARPET REPLACEMENT - FRONT FLOOR REMOVAL PROCEDURE 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket. 2. Remove the engine cover, if required. Refer to Engine Cover Replacement. 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement. 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1908 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 9. Remove the carpet/mat from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. TIGHTEN Screws to 2 Nm (18 lb. in.). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement. 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. 7. Install the engine cover, if required. Refer to Engine Cover Replacement. 8. Install the seats and the risers. Refer to Seat Replacement - Bucket in Seats. Seat Replacement - Bucket SEAT REPLACEMENT - BUCKET REMOVAL PROCEDURE 1. Remove the seat belt from the side of the seat belt guide. 2. Remove the nuts that retain the seat to the floor. 3. Disconnect the electrical connector from the power seat if equipped. 4. Remove the seat and the riser from the vehicle. 5. Remove the seat belt guide from the seat riser. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1909 6. Remove the bolts that retain the seat to the riser. 7. Remove the power seat from the seat risers if equipped. 8. Remove the manual seat adjuster wire from the seat tracks. 9. Remove the seat riser spacer nuts and bolts from the seat tracks. 10. Remove the seat riser spacer from the seat risers. INSTALLATION PROCEDURE 1. Install the seat riser spacer to the seat risers. 2. Install the seat riser spacer nuts and bolts to the seat tracks. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat riser spacer nuts and bolts to the seat tracks to 30 Nm (22 lb ft). 3. Install the manual seat adjuster wire to the seat tracks. 4. Install the power seat to the seat risers if equipped. 5. Install the seat belt guide to the seat riser. 6. Install the nuts that retain the seat to the risers. Tighten Tighten the nuts that retain the seat to the riser to 43 Nm (32 lb ft). 7. Install the seat and the seat riser in the vehicle. 8. Connect the electrical connector to the power seat if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1910 9. Install the nuts that retain the seat to the floor. Tighten Tighten the nuts that retain the seat to the floor to 43 Nm (32 lb ft). 10. Install the seat belt to the side of the seat belt guide. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1911 Access Cover: Removal and Replacement Engine Cover Replacement Engine Cover Replacement Removal Procedure 1. Remove the instrument panel extension. Refer to IP Extension Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/IP Extension Replacement) in Instrument Panel, Gages and Console. 2. Remove the floor air outlet duct. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. 3. Remove the bolts from the brackets: 1. Loosen the bolt. 2. Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. 6. Remove the engine cover. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1912 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the latch screws. Tighten the latch screws to 4 N.m (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten the engine cover bolt to 25 N.m (18 lb ft). 5. Insert the floor air outlet duct. Refer to IP Extension Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/IP Extension Replacement) in Instrument Panel, Gages and Console. 6. Insert the instrument panel extension. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. Engine Cover Guide Replacement Engine Cover Guide Replacement Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 1913 Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly. Installation Procedure 1. Install the engine cover guide assembly. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten the bolts that retain the engine cover guide to 8.5 N.m (75 lb in). 3. Install the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection Normal The compression builds up quickly and evenly to the specified compression. Leaking The compression is low on the first compression stroke. The compression builds up with the following strokes, but does not reach the specified compression. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1921 Camshaft Gear/Sprocket: Service and Repair Timing Chain and Sprockets Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. 5. Remove the timing chain and sprockets. 6. Clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the timing chain and the sprockets. 2. Remove the bolt from the crankshaft. Notice: Do not reuse the engine front cover. Oil leaks may result. 3. Install the engine front cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft End Play ........................................................................................................................................................ 0.0254 - 0.2286 mm (0.0010 - 0.0090 inch) Journal Diameter ........................................................................................................................................... 47.440 47.490 mm (1.8677 - 1.8696 inch) Journal Diameter Out-of-Round .......................................................................................................... 0.025 mm - Maximum (0.0010 inch - Maximum) Lobe Lift - Exhaust ................................................................................................................................................... 7.20 7.30 mm (0.283 - 0.287 inch) Lobe Lift - Intake ...................................................................................................................................................... 6.97 - 7.07 mm (0.274 - 0.278 inch) Runout ................................................................................................ ......................................................................................... 0.065 mm (0.0026 inch) Retainer Bolt Torque ................................................................................................................................................. .................................................... 106 inch lbs. Sprocket Bolt Torque ................................................................................................................................................. .......................................................... 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1925 Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Remove the engine cover. 2. Remove the air cleaner assembly. 3. Remove the radiator. 4. Remove the A/C condenser. 5. Remove the radiator grille. 6. Remove the valve lifters. 7. Remove the timing chain and the camshaft sprocket. 8. Remove the balance shaft drive gear. 9. Remove the camshaft. 10. Clean and inspect the camshaft and the bearings. Installation Procedure Important: Whenever a new camshaft is installed, do the following procedures: Change the engine oil. - Change the engine oil filter. - Add GM Engine Oil Supplement GM P/N 1052367 or the equivalent to the engine oil. 1. Install the camshaft into the engine block. 2. Install the balance shaft drive gear. 3. Install the timing chain and camshaft sprocket. 4. Install the valve lifters. 5. Install the A/C condenser. 6. Install the radiator grille. 7. Install the radiator. 8. Fill the engine cooling system. 9. Recharge the air conditioning system. 10. Install the air cleaner assembly. 11. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Valve Lifter Valve Lifter ........................................................................................................................................... ......................................... Hydraulic Roller Type Valve Lift Exhaust ................................................................................................................................................ ................................ 10.879 mm (0.4280 inch) Valve Lift Intake ................................................................................................................................................... ................................ 10.527 mm (0.4140 inch) Pushrod Guide Bolt Torque ................................................................................................................................................. .......................................................... 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1929 Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the lower intake manifold. 2. Remove the valve rocker arms and the valve push rods. 3. Remove the valve lifters. 4. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores. 5. Inspect the valve lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring. 6. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. 7. Clean and inspect the valve lifters and the valve pushrod guide. Installation Procedure Important: It is normal for NEW lifters to make a slight ticking noise when the engine is first started. Increasing the engine RPMs slightly to raise oil pressure should stop the noise. 1. Install the valve lifters. 2. Install the valve rocker arms and push rods. 3. Install the lower intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Rocker Arm .......................................................................................................................................... ................................................. Roller Pivot Type Rocker Arm Ratio .................................................. .................................................................................................................................................... 1.5:1 Rocker Arm Bolt Torque ................................................................................................................................................. .......................................................... 22 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1936 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Balance Shaft Rattling Noises (Cancellation) Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Page 1942 Balance Shaft: Specifications Balance Shaft Driven Gear Bolt Torque: First Pass ............................................................................................................................................. .......................................................... 15 ft. lbs. Final Pass ................................................................. ................................................................................................................................... 35 degrees Balance Shaft Retainer Bolt ................................................................................................................ ............................................................ 106 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Technical Service Bulletins > Page 1943 Balance Shaft: Service and Repair Balance Shaft Replacement Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser, if equipped. 3. Remove the valve lifter pushrod guide. 4. Remove the camshaft timing chain and sprockets. Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 5. Remove the balance shaft. 6. Clean and inspect the balance shaft. Installation Procedure 1. Install the balance shaft. 2. Install the camshaft timing chain and the camshaft sprocket. 3. Install the crankshaft position reluctor ring and the engine front cover. 4. Install the valve lifter pushrod guide. 5. Install the A/C condenser, if equipped. 6. Install the radiator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Balance Shaft Bearing Rear Bearing Journal Clearance .......................................................................................................................... 0.050 - 0.088 mm (0.0020-0.0035 inch) Rear Bearing Journal Diameter ....................................................................................................................... 38.085 - 38.100 mm (1.4994 - 1.500 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Bearing > Component Information > Specifications > Page 1947 Balance Shaft Bearing: Service and Repair Balance Shaft Bearing and/or Bushing Replacement Removal Procedure Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 1. Remove the balance shaft. 2. Remove the balance shaft rear bearing. Installation Procedure 1. Install the balance shaft rear bearing. 2. Install the balance shaft. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance Production ..................................................................................................................................................... 0.038 - 0.078 mm (0.0015-0.0031 inch) Service ......................................................................................................................................................... 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Journal Diameter .......................................................................................................................................... 57.116 57.148 mm (2.2487 - 2.2497 inch) Journal Out-of-Round Production ...................................................................................................................................... 0.007 mm - Maximum (0.0002 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Journal Taper Production ................................................................................................................................ 0.00508 mm - Maximum (0.00030 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Side Clearance ........................................................................................................................................................... 0.15 - 0.44 mm (0.006 - 0.017 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Bearing Clearance Production ..................................................................................................................................................... 0.038 - 0.078 mm (0.0015-0.0031 inch) Service ......................................................................................................................................................... 0.025 - 0.063 mm (0.0010 - 0.0025 inch) Journal Diameter .......................................................................................................................................... 57.116 57.148 mm (2.2487 - 2.2497 inch) Journal Out-of-Round Production ...................................................................................................................................... 0.007 mm - Maximum (0.0002 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Journal Taper Production ................................................................................................................................ 0.00508 mm - Maximum (0.00030 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Connecting Rod Side Clearance ................................................................................................................................ 0.15 - 0.44 mm (0.006 - 0.017 inch) Connecting Rod Nut Torque: First Pass ............................................................................................................................................. .......................................................... 20 ft. lbs. Final Pass ................................................................. ................................................................................................................................... 70 degrees Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine Block Coolant Drain Hole Plug Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Clearance - Journal #1-Production .......................................................................................................... 0.02 - 0.508 mm (0.0008-0.0020 inch) Bearing Clearance - Journal #2, #3, and #4-Production .................................................................................... 0.028 - 0.058 mm (0.0011 - 0.0023 inch) Bearing Clearance - Journal #1-Service ............................................................................................................ 0.0254 - 0.05 mm (0.0010 0.0020 inch) Bearing Clearance - Journal #2 #3 and #4-Service ........................................................................................... 0.025 - 0.063 mm (0.0010 - 0.0250 inch) End Play .............................................................................................................................................. .................... 0.050 - 0.20 mm (0.002 - 0.008 inch) Journal Diameter - Journal #1 ....................................................................................................................... 62.199 - 62.217 mm (2.4488 - 2.4495 inch) Journal Diameter - Journal #2 and #3 ........................................................................................................... 62.191 - 62.215 mm (2.4485 2.4494 inch) Journal Diameter - Journal #4 ....................................................................................................................... 62.179 - 62.203 mm (2.4480 - 2.4489 inch) Journal Out-of-Round Production ...................................................................................................................................... 0.005 mm - Maximum (0.0002 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Journal Taper - Production ................................................................................................................... 0.007 mm - Maximum (0.0003 inch - Maximum) Runout .................................................................................................................................................. 0.025 mm - Maximum (0.0010 inch - Maximum) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Bearing Cap Bolt (Preferred Method) Torque: First Pass ............................................................................................................................................. .......................................................... 15 ft. lbs. Final Pass ................................................................. ................................................................................................................................... 73 degrees Crankshaft Bearing Cap Bolt (Optional Strategy) Torque ................................................................................................................................................. ................................................................ 77 ft. lbs. Crankshaft Bearing Clearance - Journal #1-Production .......................................................................................................... 0.02 - 0.508 mm (0.0008-0.0020 inch) Bearing Clearance - Journal #2, #3, and #4-Production .................................................................................... 0.028 - 0.058 mm (0.0011 - 0.0023 inch) Bearing Clearance - Journal #1-Service ............................................................................................................ 0.0254 - 0.05 mm (0.0010 0.0020 inch) Bearing Clearance - Journal #2 #3 and #4-Service ........................................................................................... 0.025 - 0.063 mm (0.0010 - 0.0250 inch) End Play .............................................................................................................................................. .................... 0.050 - 0.20 mm (0.002 - 0.008 inch) Journal Diameter - Journal #1 ....................................................................................................................... 62.199 - 62.217 mm (2.4488 - 2.4495 inch) Journal Diameter - Journal #2 and #3 ........................................................................................................... 62.191 - 62.215 mm (2.4485 2.4494 inch) Journal Diameter - Journal #4 ....................................................................................................................... 62.179 - 62.203 mm (2.4480 - 2.4489 inch) Journal Out-of-Round Production ...................................................................................................................................... 0.005 mm - Maximum (0.0002 inch - Maximum) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Journal Taper - Production ................................................................................................................... 0.007 mm - Maximum (0.0003 inch - Maximum) Runout .................................................................................................................................................. 0.025 mm - Maximum (0.0010 inch - Maximum) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Engine Coolant Heater Bolt/Screw Torque ................................................................................................................................................. ............................................................ 18 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1966 Engine Block Heater: Service and Repair Coolant Heater Replacement Removal Procedure 1. Drain the engine coolant. 2. If not originally equipped with an engine coolant heater, remove the coolant jacket plug by using the following procedure: 2.1. Carefully tap the coolant jacket plug near the outer edge. This causes the plug to rotate in the hole. Do not score the machined surface of the hole. 2.2. Grasp the plug with pliers and pull the plug out. 3. Remove the cord from the engine coolant heater. 4. Loosen the bolt. 5. Remove the engine coolant heater. 6. Clean the core plug hole. Remove any of the following conditions: - Burrs - Compound - Paint - Rough spots Installation Procedure 1. Apply a coating of lubricant to the O-ring seal and the cleaned surface of the plug opening in the block. Use a water spray resistant, high-temperature grease lubricant (GM P/N 9985164 or equivalent). Notice: The block heater element must not touch the engine block inner wall in the installed position or damage to the engine block and the block heater could result. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1967 2. Install the engine block heater into the engine block. Position the heater element 90 degrees perpendicular (1) to the crankshaft centerline. 3. Push the engine coolant heater into the block until the outer edge is flush with the engine block surface. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the bolt until both locking wings draw tight against the inner wall of the engine block. Tighten the bolt to 1.9 Nm (17 inch lbs.). Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1968 5. Install the heater cord to the coolant heater. Route and secure the heater cord through the engine as shown. 6. Route and secure the heater cord across the engine cowl as shown. 7. Route and secure the heater cord to the VCM wiring harness. 8. Fill the reservoir with engine coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1969 9. Inspect the system for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Specifications Expansion/Freeze Plug: Specifications Engine Block Left Rear Oil Gallery Plug Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Block Left Side Oil Gallery Plug Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Engine Block Oil Gallery Plug Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Engine Block Right Rear Oil Gallery Plug Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt Torque ................................................................................................................................................. ................................................................ 70 ft. lbs. Crankshaft Pulley Bolt Torque ................................................................................................................................................. ................................................................ 43 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1976 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Removal Procedure 1. Remove the fan shroud assembly. 2. Remove the drive belt. 3. Remove the crankshaft balancer. 4. Clean and inspect all parts. Installation Procedure 1. Apply a small amount of grease to the crankshaft front cover oil seal sealing surface if reusing the seal. 2. Install the crankshaft balancer. 3. Install the drive belt. 4. Install the fan shroud assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Piston Bore Clearance Production ................................................................................................................................................... 0.018 - 0.061 mm (0.0007 - 0.0024 inch) Service ............................................................................................................................................ 0.075 mm - Maximum (0.0029 inch - Maximum) Piston Pin Clearance in Piston Production ................................................................................................................................................... 0.013 - 0.023 mm (0.0005 - 0.0009 inch) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Diameter ........................................................................................................................................................ 23.545 - 23.548 mm (0.9270 - 0.9271 inch) Fit in Connecting Rod .......................................................................................... 0.012 - 0.048 mm - Interference (0.0005 0.0019 inch - Interference) Piston Rings- End Gap Measured in Cylinder Bore Compression Ring Gap Production-Top Groove ...................................................................................................................................... 0.25 - 0.40 mm (0.010 - 0.016 inch) Production-2nd Groove ....................................................................................................................................... 0.38 - 0.58 mm (0.015 - 0.023 inch) Service-Top Groove ............................................................................................................................................ 0.25 0.50 mm (0.010 - 0.020 inch) Service-2nd Groove ............................................................................................................................................ 0.38 0.80 mm (0.015 - 0.031 inch) Piston Compression Ring Groove Clearance Production-Top ........................................................................................................................................... 0.030 0.070 mm (0.0012 - 0.0027 inch) 2nd Groove .................................................................................................................................................. 0.040 - 0.080 mm (0 0015 - 0.0031 inch) Service ......................................................................................................................................................... 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Piston Oil Ring Gap Production ........................................................................................................................................................... 0.25 - 0.76 mm (0.010 - 0.029 inch) Service ......................................................................................................................................................... 0.005 - 0.090 mm (0.0002 - 0.0035 inch) Piston Oil Ring Groove Clearance Production ................................................................................................................................................... 0.046 - 0.196 mm (0.0018 - 0.0077 inch) Service ......................................................................................................................................................... 0.046 - 0.200 mm (0.0018 - 0.0079 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Clearance in Piston Production ................................................................................................................................................... 0.013 - 0.023 mm (0.0005 - 0.0009 inch) Service ............................................................................................................................................ 0.025 mm - Maximum (0.0010 inch - Maximum) Diameter ........................................................................................................................................................ 23.545 - 23.548 mm (0.9270 - 0.9271 inch) Fit in Connecting Rod .......................................................................................... 0.012 - 0.048 mm - Interference (0.0005 0.0019 inch - Interference) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings- End Gap Measured in Cylinder Bore Compression Ring Gap Production-Top Groove ...................................................................................................................................... 0.25 - 0.40 mm (0.010 - 0.016 inch) Production-2nd Groove ....................................................................................................................................... 0.38 - 0.58 mm (0.015 - 0.023 inch) Service-Top Groove ............................................................................................................................................ 0.25 0.50 mm (0.010 - 0.020 inch) Service-2nd Groove ............................................................................................................................................ 0.38 0.80 mm (0.015 - 0.031 inch) Compression Ring Groove Clearance Production-Top ........................................................................................................................................... 0.030 0.070 mm (0.0012 - 0.0027 inch) Production 2nd Groove ............................................................................................................................... 0.040 - 0.080 mm (0 0015 - 0.0031 inch) Service ......................................................................................................................................................... 0.030 - 0.085 mm (0.0012 - 0.0033 inch) Oil Ring Gap Production ........................................................................................................................................................... 0.25 - 0.76 mm (0.010 - 0.029 inch) Service ......................................................................................................................................................... 0.005 - 0.090 mm (0.0002 - 0.0035 inch) Oil Ring Groove Clearance Production ................................................................................................................................................... 0.046 - 0.196 mm (0.0018 - 0.0077 inch) Service ......................................................................................................................................................... 0.046 - 0.200 mm (0.0018 - 0.0079 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1991 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1992 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Rocker Arm .......................................................................................................................................... ................................................. Roller Pivot Type Rocker Arm Ratio .................................................. .................................................................................................................................................... 1.5:1 Rocker Arm Bolt Torque ................................................................................................................................................. .......................................................... 22 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1996 Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the valve rocker arm and the valve pushrod. 3. Clean and inspect the valve rocker arm and the valve pushrod. Installation Procedure 1. Install the valve rocker arm and the valve pushrod. 2. Install the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Remove the engine cover. 2. Remove the oil filler tube and bolt 3. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 4. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 5. Remove the rear spark plug wire retainer from the support. 6. Remove the valve rocker arm cover. 7. Clean all sealing surfaces and the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2001 Installation Procedure 1. Install the valve rocker arm cover and bolts. 2. Install the PCV valve hose assembly to the intake manifold and in the valve rocker arm cover. 3. Install the rear spark plug wire retainer to the support Notice: Refer to Fastener Notice in Service Precautions. 4. Install the oil filler tube and bolt. Tighten the bolt to 25 Nm (18 ft. lbs.). 5. Connect the ECT sensor electrical connector. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2002 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Remove the engine cover. 2. Disconnect the spark plug wires for the right side of the engine from the distributor cap. 3. Remove the PCV tube from the valve rocker arm cover and the air cleaner outlet duct. 4. Remove the engine wiring harness bracket from the EVAP canister purge solenoid valve stud. 5. Move the engine wiring harness aside. 6. Remove the right valve rocker arm cover. 7. Clean all sealing surfaces and the valve rocker arm cover. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2003 1. Install the right valve rocker arm cover and bolts. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine wiring harness bracket and nut to EVAP canister purge solenoid valve stud. Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.). 3. Install the PCV hose in the valve rocker arm cover and the air cleaner outlet duct. 4. Connect the spark plug wires to the distributor cap. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Customer Interest for Valve Guide: > 1539013 > Jul > 04 > Engine SES Lamp ON/Misfire DTC' Set Towing Uphill Valve Guide: Customer Interest Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Guide: > 1539013 > Jul > 04 > Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Valve Guide: All Technical Service Bulletins Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Angle ................................................................................................................................................... .............................................................. 46 degrees Runout ...................................................................................................................................................... 0.05 mm - Maximum (0.002 inch - Maximum) Seat Width - Exhaust ............................................................................................................................................. 1.651 2.489 mm (0.065 - 0.098 inch) Seat Width - Intake ................................................................................................................................................ 1.016 1.651 mm (0.040 - 0.065 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Free Length ......................................................................................................................................... ............................................... 51.3 mm (2.02 inch) Installed Height Exhaust ............................................................................................................................................................ 42.92 - 43.43 mm (1.670 - 1.700 inch) Intake ..................................................................................... .......................................................................... 42.92 - 43.43 mm (1.670 - 1.700 inch) Spring Pressure Closed ........................................................................................................................................... 338 - 374 N at 43.2 mm (76 - 84 lbs. at 1.70 inch) Open .......................................................................................................................................... 832 - 903 N at 32.3 mm (187 - 203 lbs. at 1.27 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2023 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required J22794 Spark Plug Port Adapter - J38606 Valve Spring Compressor - J5892-D Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Notice: Completely engage the J38606 jaws on the valve spring. The J38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2024 10. Use J38606 when J5892-D will not fit. 11. Remove the valve keys (1). 12. Carefully release the valve spring tension. 13. Remove the J5892-D or J38606 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure 1. Install the valve seals (4). 2. Install the valve spring (3). 3. Install the valve spring cap (2) on the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2025 by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 4. To press the valve spring (3) use the J5892-D. Notice: Completely engage the J38606 jaws on the valve spring. The J38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 5. Use the J38606 if the clearance does not permit use of the J5892-D. 6. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 7. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 8. Remove the J5892-D or the J38606. 8.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 8.2. Tap the end of the valve stem with a plastic faced hammer in to seat the valve stem keys, if necessary. 9. Remove the J22794. 10. Install the spark plugs. 11. Install the valve rocker arms to the cylinder head. 12. Install the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 1539013 > Jul > 04 > Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Valve: Customer Interest Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 1539013 > Jul > 04 > Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Valve: All Technical Service Bulletins Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2039 Valve: Specifications Valve System Valve Face Angle................................................................................................................................. .............................................................. 45 degrees Valve Head ............................................................................................................................................ 0.79 mm Minimum (1 0.031 inch - Minimum) Valve Lash .................................................................................. ................................................................................................ Net Lash-No Adjustment Valve Lift Exhaust ................................................................................................................................................ ................... 10.879 mm (0.4280 inch) Valve Lift - Intake .................................................................... .................................................................................................. 10.527 mm (0.4140 inch) Valve Lifter .............................................................................................................................................................. ...................... Hydraulic Roller Type Rocker Arm ............................................................................... ............................................................................................................ Roller Pivot Type Rocker Arm Ratio .................................................................................................................................................... .................................................. 1.5:1 Valve Seat Angle ..................................................................... ......................................................................................................................... 46 degrees Valve Seat Runout .................................................................................................................................... 0.05 mm - Maximum (0.002 inch - Maximum) Valve Seat Width Exhaust ............................................................................................................................................................ 1.651 - 2.489 mm (0.065 - 0.098 inch) Intake ..................................................................................... .......................................................................... 1.016 - 1.651 mm (0.040 - 0.065 inch) Valve Spring Free Length .................................................................................................................... .............................................. 51.3 mm (2.02 inch) Valve Spring Installed Height Exhaust ............................................................................................................................................................ 42.92 - 43.43 mm (1.670 - 1.700 inch) Intake ..................................................................................... .......................................................................... 42.92 - 43.43 mm (1.670 - 1.700 inch) Valve Spring Pressure Closed ........................................................................................................................................... 338 - 374 N at 43.2 mm (76 - 84 lbs. at 1.70 inch) Open .......................................................................................................................................... 832 - 903 N at 32.3 mm (187 - 203 lbs. at 1.27 inch) Valve Stem Clearance - Exhaust Production ................................................................................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Service ......................................................................................................................................................... 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Valve Stem Clearance - Intake Production ................................................................................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Service ......................................................................................................................................................... 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Valve Stem Oil Seal installed Height ......................................................................................................................... 1 - 2 mm (0.03937 - 0.07874 inch) (Measured from the Top of the Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2045 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2046 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2047 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2050 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2051 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2052 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2053 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belts) is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2054 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step verifies that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt. When removing the drive belt(s) the water pump may not be operating and cause the engine to overheat. Also DTCs may set if the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or strings in the drive belt grooves. Pilling occurs from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley. Use a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the correct installation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2055 procedure. 10. Inspection of the fasteners eliminates the installment of incorrect: bolts, nuts, spacers, or washers. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged, or if there is no excessive pilling will be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by mix-positioning the drive belt(s) by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2056 Diagnostic Aids If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate correctly. If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the correct tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for an incorrectly aligned pulley using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating correctly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2057 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belts) is to ensure that it is not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for correct operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2058 Diagnostic Aids A loose or incorrect installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent verify the accessory drive components by varying their loads. Ensure the accessory components are operated to their maximum capacity. An overcharged A/C system or power steering system with: a pinched hose, an incorrect fluid, or a failed generator are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine verifies the noise is related to the drive belt or an accessory drive component. If the drive belt is removed, the water pump may not operate. Without the water pump the engine may overheat. DTCs may set when the engine is operating with the drive belt removed. 4. This test verifies that an accessory drive component does not have a seized bearing. Remove the belt and test the bearings for smooth turning in the accessory drive components. Test the accessory drive components with the engine operating, vary the load on the components to verify that the components operate correctly. 5. This test is to verify that the drive belt tensioner operates correctly. If the drive belt tensioner is not operating correctly, correct belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working correctly. Also if an incorrect length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from incorrect mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a pulley that is incorrectly aligned using a straight edge in the pulley grooves across two or three pulleys. If an incorrectly aligned pulley is found refer to that accessory drive component for the correct installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Drive Belt Vibration Drive Belt Vibration Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2059 Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Drive Belt Whine Diagnosis Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2060 Diagnostic Aids The drive belt(s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. DTCs may set if the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the correct inspection and replacement procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2061 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the air cleaner outlet duct from the throttle body. 3. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise. 4. Remove the drive belt. 5. Slowly release the tension on the drive belt tensioner arm. Installation Procedure 1. Route the belt over all the pulleys except the tensioner arm. 2. Observe drive belt routing for vehicles without air conditioning. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2062 3. Observe drive belt routing for vehicles with air conditioning. 4. Install a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counter clockwise. 5. Install the drive belt over the drive belt tensioner pulley. 6. Slowly release the tension on the tensioner arm. 7. Inspect for the drive belt being properly installed on the pulleys. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2063 8. Avoid mix-positioning the drive belt by one or more grooves. 9. Confirm for the proper drive belt size and the correct drive belt routing by observing the location of the fix pointer and the index marks on the drive belt tensioner. With a new drive belt installed, the fix pointer should align within the indentation on the drive belt tensioner. 10. With a used drive belt installed, the fix pointer should not align past the index mark. 11. Install the air cleaner outlet duct. 12. Install the air cleaner assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt Torque ................................................................................................................................................. ................................................................ 37 ft. lbs. Engine Wiring Harness Bracket Bolt to Generator and Drive Belt Tensioner Bracket Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2067 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the belt tensioner arm will move. Do not replace the belt tensioner because of movement in the belt tensioner arm. 1. Remove the drive belt. 2. Position a 3/8 inch drive wrench on the drive belt tensioner arm and rotate the arm counterclockwise 3. Move the drive belt tensioner through its full travel. - The movement should feel smooth. - There should be no binding. - The tensioner should return freely. 4. If any binding is observed, replace the drive belt tensioner. 5. Install the drive belt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2068 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the attaching bolt. Tighten the tensioner assembly bolt to 50 Nm (37 ft. lbs.). 3. Install the drive belt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Engine Accessory Bracket Engine Lift Bracket Bolt (Special Tool J41427) Torque ................................................................................................................................................. .......................................................... 11 ft. lbs. Engine Lift Front Bracket Stud Torque ................................................................................................................................................. .......................................................... 26 ft. lbs. Engine Mount Bracket Bolt to Engine Torque ................................................................................................................................................. .......................................................... 47 ft. lbs. Engine Mount Bracket to Frame Bolt (AWD) Torque ................................................................................................................................................. .......................................................... 35 ft. lbs. Engine Mount Bracket to Frame Nut (AWD) Torque ................................................................................................................................................. .......................................................... 31 ft. lbs. Engine Mount Frame Bracket Through-bolt Torque ................................................................................................................................................. .......................................................... 50 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Mount Bolt to Frame (AWD) Torque ................................................................................................................................................. .......................................................... 44 ft. lbs. Bolt to Frame (AWD) Torque ................................................................................................................................................. .......................................................... 35 ft. lbs. Nut to Frame (RWD) Torque ................................................................................................................................................. .......................................................... 31 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2075 Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Inspect for loose or missing bolts at the following locations: - The engine mount bracket to the engine - The engine mount to the engine bracket through-bolts - The engine mount to frame bracket bolts 3. Replace loose or missing bolts. Notice: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage. 4. In order to access the square tab on the left side of the engine remove the oil filter adapter. 5. In order to access the square tab on the right side of the engine remove the starter. 6. Using a jack on the square tab at the rear of the engine block (left side shown) raise the engine in order to complete the following tasks: - Remove weight from the engine mount. - Place a slight tension on the rubber cushion. - Observe the engine mount while raising the engine. 7. Replace the engine mount if the following conditions exist: - Heat check cracks cover the hard rubber surface. - The rubber cushion is separated from the metal plate of the engine mount. - There is a split through the rubber cushion. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2076 8. Replace the starter, if removed. 9. Replace the oil filter adapter, if removed. 10. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Removal Procedure Notice: Refer to Engine Mounting Notice in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the oil filter adapter. 4. Remove the engine mount through-bolt and nut for the side being replaced. Notice: Refer to Engine Lifting Notice in Service Precautions. 5. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine only enough to remove the engine mount. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2079 6. Remove the bolts for the engine mount bracket to the engine. Access the upper two bolts for the right engine mount bracket through the fender wheelhouse. 7. Remove the engine mount bracket. 8. For AWD vehicle remove the bolts for the engine mount to the frame (left side shown). 9. Remove the engine mount. 10. For a RWD vehicle left side remove the bolts and the nuts for the engine mount to the frame bracket (left side shown). 11. If necessary, remove the left side engine mount frame bracket from the frame. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2080 1. For AWD vehicle install the engine mount to the frame (left side shown). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the AWD vehicle engine mount to the frame bolts. Tighten the AWD vehicle engine mount to frame bolts to 59 Nm (44 ft. lbs.). 3. If removed, install the RWD vehicle left side bolts, nuts and engine mount frame bracket to the frame. - Tighten the engine mount frame bracket bolts to 47 Nm (35 ft. lbs.). - Tighten the engine mount frame bracket nuts to 42 Nm (31 ft. lbs.). 4. Install the RWD vehicle left side engine mount, the bolts, and the nuts to the frame bracket. - Tighten the engine mount to frame bolts to 47 Nm (35 ft. lbs.). - Tighten the engine mount to frame nuts to 42 Nm (31 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2081 5. Install the engine mount bracket to the engine. 6. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 64 Nm (47 ft. lbs.). 7. Lower the engine. 8. Install the engine mount through-bolt and the nut. Tighten the engine mount through-bolt nuts to 68 Nm (50 ft. lbs.). 9. Install the oil filter adapter. 10. Lower the vehicle. 11. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2082 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Removal Procedure Notice: Refer to Engine Mounting Notice in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Remove the right front tire. 4. Remove the right fender wheelhouse extension. 5. Remove the starter. 6. Remove the engine mount through-bolt and nut. Notice: Refer to Engine Lifting Notice in Service Precautions. 7. Using a jack on the square tab (left side shown) at the rear of the engine block, raise the engine only enough to remove the engine mount. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2083 8. Remove the bolts for the engine mount bracket to the engine. Access the upper two bolts for the right engine mount bracket through the fender wheelhouse. 9. Remove the engine mount bracket. 10. For AWD vehicle remove the bolts for the engine mount to the frame (left side shown). 11. Remove the engine mount. 12. For a RWD vehicle right side remove the bolts and the nuts for the engine mount to the frame. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2084 1. Install the AWD vehicle engine mount to the frame bolts. Tighten the AWD vehicle engine mount to frame bolts to 59 Nm (44 ft. lbs.). 2. Install the RWD vehicle right side engine mount, the bolts, and the nuts to the frame. - Tighten the engine mount to frame bolts to 47 Nm (35 ft. lbs.). - Tighten the engine mount to frame nuts to 42 Nm (31 ft. lbs.). 3. Install the engine mount bracket to the engine. 4. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 64 Nm (47 ft. lbs.). 5. Lower the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left > Page 2085 6. Install the engine mount through bolt and the nut. Tighten the engine mount through-bolt nuts to 68 Nm (50 ft. lbs.). 7. Install the starter. 8. Install the right fender wheelhouse extension. 9. Install the right front tire. 10. Lower the vehicle. 11. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Belt Idler Pulley Bolt Torque ................................................................................................................................................. ................................................................ 37 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Right Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Right Drive Belt Idler Pulley Replacement - Right Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley from the generator mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the drive belt idler pulley and bolt to the generator mounting bracket. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley Replacement - Right > Page 2091 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Without Air Conditioning Drive Belt Idler Pulley Replacement - without Air Conditioning Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley from the power steering pump mounting bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the drive belt idler pulley and bolt to the power steering pump mounting bracket. Tighten the bolt to 50 Nm (37 ft. lbs.). 2. Install the drive belt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - at Normal Operating Temperature ................................................................................................................... 42 kPa (6 psig) at 1,000 RPM Minimum - at Normal Operating Temperature ............................................................................................................... 125 kPa (18 psig) at 2,000 RPM Minimum - at Normal Operating Temperature ................................................................................................................ 166 kPa (24 psig)at 4,000 RPM Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2096 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: - Engine oil diluted by moisture or unburned fuel mixtures - Improper engine oil viscosity for the expected temperature - Incorrect or faulty oil pressure gage sensor - Incorrect or faulty oil pressure gage - Plugged oil filter - Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psig, minimum, at 1,000 RPM 7.2. 125 kPa (18 psig, minimum, at 2,000 RPM 7.3. 166 kPa (24 psig, minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty - Malfunctioning oil pump pressure relief valve - Oil pump screen loose, plugged, or damaged - Excessive bearing clearance - Cracked, porous or restricted oil galleries - Engine block oil gallery plugs missing or incorrectly installed - Broken valve lifters Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Dip Stick Tube Fill Tube Bolt Torque ................................................................................................................................................. .......................................................... 18 ft. lbs. Oil Level Indicator Tube Bolt Torque ................................................................................................................................................. .................................................... 106 inch lbs. Oil Level Indicator Tube Bolt to Transmission Fluid Fill Tube Torque ................................................................................................................................................. .................................................... 106 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2100 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the engine cover. 2. Remove the oil level indicator. 3. Remove the bolt holding the oil level indicator tube to the transmission fluid fill tube. 4. Remove the upper half of the oil level indicator tube from the lower half. 5. Clean the old sealer from the tubes. 6. Remove the oil level indicator tube bolt. 7. Remove the oil level indicator tube from the engine using a twisting motion. 8. Clean the old sealer from the oil level indicator tube and the engine block. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2101 Installation Procedure 1. Install the lower half of the oil level indicator tube to the engine. 2. Apply sealer, GM P/N 12346004 or equivalent, on the upper oil level indicator tube to the area where the tube fits into the lower half. 3. Install the oil level indicator tube upper half to the lower half. Notice: Refer to Fastener Notice in Service Precautions. 4. Secure the engine oil level indicator tube to the transmission fluid fill tube with the bolt. Tighten the bolt to 12 Nm (106 inch lbs.). 5. Install the oil level indicator. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2106 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2107 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 4.2L (4.5 Qt) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2110 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Viscosity ........................................................... .......................................................................................................................................................... 5W-30 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2111 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise the vehicle and support with safety stands. Refer to Vehicle Lifting. 2. Remove the oil pan drain plug and drain the engine oil in a suitable container. 3. Remove the engine oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the engine oil filter gasket with clean engine oil. 2. Install the engine oil filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2112 3. Follow the tightening instructions on the oil filter. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the drain plug to the oil pan. Tighten the oil pan plug to 25 Nm (18 ft. lbs.). 5. Remove the safety stands and lower the vehicle. 6. Fill the engine with the proper capacity and quality of engine oil. 7. Operate the engine, check for leaks and oil pressure. 8. Check the oil level and add as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement Oil Filter: Service and Repair Oil Filter Bypass Valve Replacement Oil Filter Bypass Valve Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter. 4. Remove the oil filter adapter. 5. Using a suitable prying tool remove the oil filter bypass valve. 6. Clean and inspect valve bore for damage. Installation Procedure Caution: Refer to Safety Glasses Caution in Service Precautions. 1. Install a NEW oil filter bypass valve using the following procedure: 1.1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. 1.2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 1.3. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart. 2. Install the oil filter adapter. 3. Install the oil filter. 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement > Page 2119 Oil Filter: Service and Repair Draining Fluids and Oil Filter Removal Draining Fluids and Oil Filter Removal 1. Remove the oil pan drain plug and allow the engine oil to drain into a suitable container. 2. Remove the oil filter (if applicable). 3. Discard the oil filter (if applicable). 4. Remove both the engine block coolant drain hole plugs and allow the coolant to drain into a suitable container. Engine Flywheel Removal Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Oil Filter Bypass Valve Replacement > Page 2120 1. Remove the engine flywheel bolts. 2. Remove the engine flywheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolt Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Oil Filter Fitting Torque ................................................................................................................................................. ................................................................ 41 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2124 Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Position a suitable container to catch the engine oil. 3. Remove the oil filter. 4. Disconnect the engine oil cooler pipes from the oil filter adapter. 5. Remove the oil filter adapter. Installation Procedure 1. Install the oil filter adapter with a NEW gasket. 2. Install the engine oil cooler pipes to the oil filter adapter. 3. Install the oil filter. 4. Lower the vehicle. 5. Operate the vehicle and check for leaks. 6. Check the oil level and add as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications Oil Line: Specifications Oil Cooler Line Oil Cooler Line Clip Bolt Torque ................................................................................................................................................. ........................................ 10 Nm (89 inch lbs.) Engine Oil Cooler Lines to Oil Filter Adapter Assembly Bolt Torque ................................................................................................................................................. ........................................... 35 Nm (26 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications > Page 2128 Oil Line: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine walls it is still hot Service the engine when it is cool. 1. Place a drain pan under the oil filter adapter. 2. Disconnect the oil cooler lines from the oil filter adapter assembly. 3. Remove the oil cooler line to engine clip bolt. 4. Remove the oil cooler lines from the engine clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications > Page 2129 5. Disconnect the oil cooler lines from the radiator connector fitting by doing the following: - Use a small pick-type tool or a screwdriver to release one of the open ends of the retaining clip from the connector fitting. - Disconnect the retaining clip from the connector fitting. - Discard the clips. 6. Remove the engine oil cooler lines. 7. Clean all of the components with a suitable solvent. Dry the components with compressed air. 8. Inspect the following for damage or distortion: - The connector fittings - The connectors - The engine oil cooler lines Installation Procedure Important: Inspect the cooler line for a damaged or missing plastic cap. If the plastic cap is damaged or missing, replace it with a new plastic cap. 1. Install the engine oil cooler lines. 2. Install the new retaining clips into the radiator connector fittings. 2.1. Using your thumb and forefinger, insert a new retaining clip into one of the three recesses in the connector fitting (1). 2.2. With one end of the retaining clip engaged in the connector fitting slot, use your thumb to rotate the retaining clip around the connector fitting (2). 2.3. Snap the clip into place in the connector fitting (3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications > Page 2130 3. Connect the engine oil cooler lines to the connector fittings. - Verify that a click is heard or felt. - Pull back sharply on the cooler lines in order to assure that the line fastens into the connector fittings. 4. Connect the engine oil cooler lines to the engine clip. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the engine clip bolt. Tighten the engine clip bolt to 10 Nm (89 inch lbs.). 6. Install the engine oil cooler lines to the oil filter adapter assembly. Tighten the oil cooler lines to oil filter adapter assembly bolt to 35 Nm (26 ft. lbs.). 7. Start the engine. Check the oil cooler lines for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolt and Nut Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Oil Pan Drain Plug Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Oil Pan Alignment at Rear of Engine Block Maximum ............................................................................................................................................. .............................................. 0.3 mm (0.011 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2134 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the oil level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan drain plug and drain the engine oil into a suitable container. 5. Remove the oil filter. 6. Remove the bolt holding the oil cooler pipes bracket to the oil pan. 7. Remove the oil filter adapter. 8. Remove the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes. 9. Remove the Crankcase Position sensor wiring harness from the retainer. 10. Remove the starter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2135 11. Remove the transmission cover. 12. Remove the access plugs for the oil pan rear nuts. 13. Remove the transmission to oil pan bolts. 14. Remove the oil pan from the engine. 15. Clean all sealing surfaces on the engine and the oil pan. Installation Procedure Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. 1. Install the oil pan to the engine. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2136 2. Install the transmission to oil pan bolts and nuts. Tighten the bolts to 47 Nm (34 ft. lbs.). 3. Install the access plugs for the oil pan rear nuts. 4. Install the transmission cover. Tighten the bolts to 12 Nm (106 inch lbs.). 5. Install the starter motor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2137 6. Install the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes. Tighten the bolts to 10 Nm (89 inch lbs.). 7. Install the CKP sensor wiring harness in the retainer. 8. Install the oil filter adapter. 9. Install the oil cooler pipes bracket bolt. Tighten the bolts to 10 Nm (89 inch lbs.). 10. Install the oil filter. 11. Install the oil pan drain plug. Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 12. Lower the vehicle. 13. Fill the crankcase with engine oil. 14. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC displays the engine oil pressure as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine oil pressure. The engine oil pressure gage defaults to 0 kPa (0 psi) or below if: ^ The PCM detects a malfunction in the engine oil pressure sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Specifications > Page 2147 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Specifications > Page 2148 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt Torque ................................................................................................................................................. .......................................................... 106 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - at Normal Operating Temperature ................................................................................................................... 42 kPa (6 psig) at 1,000 RPM Minimum - at Normal Operating Temperature ............................................................................................................... 125 kPa (18 psig) at 2,000 RPM Minimum - at Normal Operating Temperature ................................................................................................................ 166 kPa (24 psig)at 4,000 RPM Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2156 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: - Engine oil diluted by moisture or unburned fuel mixtures - Improper engine oil viscosity for the expected temperature - Incorrect or faulty oil pressure gage sensor - Incorrect or faulty oil pressure gage - Plugged oil filter - Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: Specification 7.1. 42 kPa (6 psig, minimum, at 1,000 RPM 7.2. 125 kPa (18 psig, minimum, at 2,000 RPM 7.3. 166 kPa (24 psig, minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty - Malfunctioning oil pump pressure relief valve - Oil pump screen loose, plugged, or damaged - Excessive bearing clearance - Cracked, porous or restricted oil galleries - Engine block oil gallery plugs missing or incorrectly installed - Broken valve lifters Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2161 Intake Manifold: Specifications Accelerator Control Cable Bracket Stud to Intake Manifold Torque ................................................................................................................................................. ............................................................ 53 inch lbs. Air Conditioning (A/C) Hose Bracket Nut to Intake Manifold Torque ................................................................................................................................................. ............................................................ 44 inch lbs. Engine Wiring Harness Bracket Nut to Intake Manifold Torque ................................................................................................................................................. .......................................................... 106 inch lbs. Lower Intake Manifold Bolt Torque: First Pass ............................................................................................................................................. ....................................................... 27 inch lbs. Second Pass ............................................................ ................................................................................................................................. 106 inch lbs. Final Pass ............................................................................................................................................ .......................................................... 11 ft. lbs. Upper Intake Manifold Stud Torque: First Pass ............................................................................................................................................. ....................................................... 44 inch lbs. Final Pass ................................................................. .................................................................................................................................. 80 inch lbs. Intake Manifold Surface Flatness ................................................................................................................. 0.10 mm - Maximum (0.004 inch - Maximum) Tightening Sequence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower Intake Manifold: Service and Repair Intake Manifold Replacement - Lower Intake Manifold Replacement - Lower Removal Procedure 1. Disconnect the battery negative cable. 2. Remove the engine cover. 3. Drain the cooling system. 4. Remove the air cleaner assembly. 5. Remove the air cleaner outlet duct from the throttle body assembly. 6. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. 7. Perform this step if the vehicle is equipped with a cruise control. Disconnect the cruise control cable from the throttle shaft, and from the accelerator control cable bracket. 8. Disconnect PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 9. Remove the nut holding the A/C hose bracket to the intake manifold stud, if equipped. 10. Remove the nut holding the engine wiring harness bracket to the intake manifold stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2164 11. Disconnect the following electrical connectors: - The A/C compressor clutch, if equipped (1) - The A/C high pressure cutoff switch, if equipped (5) - The Throttle Position (TP) sensor (2) - The Idle Air Control (IAC) motor (3) - The fuel meter body assembly connector (4) 12. Disconnect the following electrical connectors: - The Manifold Absolute Pressure (MAP) sensor (4) - The EVAP canister purge solenoid valve (1) 13. Remove the ground wire (2) from the stud at the water outlet. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2165 14. Remove the nut, and remove the engine wiring harness bracket from the stud, at the EVAP canister purge solenoid valve. 15. Move and secure the engine wire harness out of the way. 16. Remove the EVAP canister purge valve. 17. Remove the radiator inlet hose at the water outlet. 18. Remove the heater hose from the intake manifold. 19. Remove the water pump inlet hose from the intake manifold. 20. Disconnect the vacuum hose from the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2166 21. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket. 22. Remove the accelerator control cable bracket from the throttle body and the intake manifold. 23. Remove the distributor. 24. Disconnect the fuel supply, and disconnect the return pipes, at the rear of the intake manifold. 25. Remove the Ignition Control Module (ICM). 26. In order to remove the front intake manifold bolt, perform the following steps: 26.1. Remove the drive belt. 26.2. Remove the A/C compressor side brace. 26.3. Loosen the nut for the power steering pump rear bracket. 26.4. Remove the oil filler tube bracket bolt and the oil filler tube. 26.5. Remove the bolts and the nut for the power steering pump mounting bracket. 26.6. Leave the A/C compressor, if equipped, and the power steering pump on the bracket. 26.7. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2167 27. Remove the lower intake manifold. 28. Clean all sealing surfaces and the intake manifold. 29. If the intake manifold requires replacement, refer to Intake Manifold. Installation Procedure 1. Install the lower intake manifold. 2. Reposition the power steering pump mounting bracket. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump mounting bracket three bolts and the nut. Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 Nm (30 ft. lbs.). 4. Install A/C compressor side brace and bolts. 4.1. Tighten the A/C compressor side brace bolt to 50 Nm (37 ft. lbs.). 4.2. Tighten the side brace bolt to the generator bracket to 25 Nm (18 ft. lbs.). 5. Install the oil filler tube and bolt. Tighten the oil filler tube bolt to 25 Nm (18 ft. lbs.). 6. Install the drive belt. 7. Install the EVAP canister purge valve. 8. Install the fuel supply and return pipes to the rear of the intake manifold. Important: In order to install the distributor for the correct engine timing, position the engine to number one cylinder top dead center. 9. Remove the spark plug for number one cylinder. 10. Rotate the crankshaft until number one cylinder is in the compression stroke. 11. Align the 2 reference marks on the crankshaft balancer (1, 4) with the 2 alignment marks (2, 3) on the front cover. 12. Install the spark plug. 13. Install the distributor. 14. Install the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2168 15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.). 16. Install the vacuum hose to the intake manifold. 17. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket. Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2169 18. Install the water pump inlet hose to the intake manifold. 19. Install the heater hoses. 20. Install the radiator inlet hose to the water outlet. 21. Position the engine wiring harness. 22. Connect the following electrical connectors: - The A/C compressor clutch, if equipped (1) - The A/C high pressure cutoff switch, if equipped (5) - The Throttle Position (TP) sensor (2) - The Idle Air Control (IAC) motor (3) - The fuel meter body assembly connector (4) 23. Connect the following electrical connectors: - The Manifold Absolute Pressure (MAP) sensor (4) - The EVAP canister purge solenoid valve (1) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2170 24. Install the ground wire (2) and the nut to the water outlet stud. 25. Tighten the ground wire nut to 19 Nm (14 ft. lbs.). 26. Install the nut and the engine wiring harness bracket to the stud for the EVAP canister purge valve. Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.). 27. Install the nut and the engine wiring harness bracket to the intake manifold stud. Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.). 28. Install the nut and the A/C hose bracket to the intake manifold stud, if equipped. Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2171 29. Install the PCV valve hose assembly to the intake manifold and the valve rocker arm cover. 30. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. 31. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. 32. Refill the cooling system. 33. Install air cleaner outlet duct to the throttle body. 34. Install the air cleaner assembly. 35. Connect the battery negative cable. 36. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2172 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Intake Manifold Replacement - Upper Removal Procedure Important: You do not have to remove the upper intake manifold in order to remove the lower intake manifold. 1. Remove the engine cover. 2. Remove the air cleaner outlet duct from the throttle body. 3. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. 4. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator control cable bracket. 5. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 6. Remove the nut holding the A/C hose bracket, if equipped to the intake manifold stud. 7. Remove the A/C hose bracket from the stud. 8. Remove the nut holding the engine wiring harness bracket to the intake manifold stud. 9. Remove the engine wiring harness bracket from the stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2173 10. Disconnect the following electrical connectors: - The A/C compressor clutch, if equipped (1) - The A/C high pressure cutoff switch, if equipped (5) - The throttle position (TP) sensor (2) - The idle air control (IAC) motor (3) - The fuel meter body assembly connector (4) 11. Disconnect the following electrical connectors: - The Manifold Absolute Pressure (MAP) sensor (4) - The EVAP canister purge solenoid valve (1) 12. Remove the engine wiring harness bracket from the stud at the EVAP canister purge solenoid valve. 13. Move and secure the engine wiring harness out of the way. 14. Remove the EVAP canister purge valve. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2174 15. Disconnect the vacuum hose from the intake manifold. 16. Remove the bolt holding the transmission fluid filler tube to the accelerator control cable bracket. 17. Remove the accelerator control cable bracket from the throttle body and the intake manifold. 18. Remove the fuel lines from the fuel meter body assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2175 19. Remove the studs for the upper intake manifold. 20. Remove the upper intake manifold. 21. Remove the upper intake manifold gasket from the groove. 22. Discard the gasket. 23. Remove the seal from the fuel meter body assembly. 24. Discard the seal. Important: Do not immerse the assembled upper intake manifold in cleaning solvent. 25. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent. 26. Inspect the upper intake manifold for the following: - Cracks or other damage to the exterior - Cracking or damage to the gasket grooves - Loose or damaged bolt hole thread inserts Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2176 27. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold. 28. Remove and discard the seal. 29. Remove the throttle body if replacing the upper intake manifold. 30. Remove the MAP sensor if replacing the upper intake manifold. Installation Procedure 1. Install the throttle body, if removed. 2. Install the MAP sensor, if removed. 3. Install the PCV valve cover, if removed, using the following procedure: 3.1. Install a NEW seal (O-ring) on the PCV valve cover. 3.2. Lubricate the seal with clean engine oil. 3.3. Install the PCV valve cover in the upper intake manifold. 3.4. Turn and lock the PCV valve cover in position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2177 4. Install a NEW seal on the fuel meter body assembly. 5. Lubricate the seal with clean engine oil. 6. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold. 7. Install the upper intake manifold onto the lower intake manifold. 8. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the threads of the upper intake manifold attaching bolts. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the upper intake manifold attaching studs. 9.1. Tighten the upper intake manifold attaching studs on the first pass to 5 Nm (44 inch lbs.). 9.2. Tighten the upper intake manifold attaching studs on the final pass to 9 Nm (80 inch lbs.). 10. Install the fuel lines to the fuel meter body assembly. 11. Install the EVAP canister purge valve. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2178 12. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten the accelerator control cable bracket nuts and studs to 12 Nm (106 inch lbs.). 13. Connect the vacuum hose to the intake manifold. 14. Install the transmission fluid fill tube and bolt to the accelerator control cable bracket. Tighten the transmission fluid fill tube bolt 6 Nm (53 inch lbs.). 15. Position the engine wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2179 16. Connect the following electrical connectors: - The A/C compressor clutch, if equipped (1) - The A/C high pressure cutoff switch, if equipped (5) - The Throttle Position (TP) sensor (2) - The Idle Air Control (IAC) motor (3) - The fuel meter body assembly connector (4) 17. Connect the following electrical connectors: - The Manifold Absolute Pressure (MAP) sensor (4) - The EVAP canister purge solenoid valve (1) 18. Install the engine wiring harness bracket and nut to the intake manifold stud. Tighten the engine wiring harness bracket nut to 12 Nm (106 inch lbs.). 19. Install the A/C hose bracket and nut, if equipped to the intake manifold stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement - Lower > Page 2180 Tighten the A/C hose bracket nut to 5 Nm (44 inch lbs.). 20. Install the engine wiring harness bracket and the nut onto the stud at the EVAP canister purge solenoid valve. Tighten the engine wiring harness bracket nut to 8 Nm (71 inch lbs.). 21. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover. 22. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. 23. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. 24. Install the air cleaner outlet duct to the throttle body assembly. 25. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC displays the engine oil pressure as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine oil pressure. The engine oil pressure gage defaults to 0 kPa (0 psi) or below if: ^ The PCM detects a malfunction in the engine oil pressure sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications Crankshaft Rear Oil Seal Rear Oil Seal Housing Bolt and Nut Torque ................................................................................................................................................. .................................................... 106 inch lbs. Rear Oil Seal Housing Retainer Stud Torque ................................................................................................................................................. ...................................................... 53 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Crankshaft Rear Oil Seal Replacement Tools Required J35621-B Rear Main Seal Installer Removal Procedure 1. Remove the transmission assembly. 2. Remove the engine flywheel. 3. Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing. Insert a suitable tool into the access notches and then carefully pry the crankshaft rear oil seal from the crankshaft rear oil seal housing. 4. Discard the crankshaft rear oil seal. 5. Clean off any dirt or rust in the area. Installation Procedure 1. Apply a small amount (2 to 3 drops) of clean engine oil to the bore of the crankshaft rear oil seal housing. 2. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the engine flywheel pilot flange. 3. Apply a small amount (1 drop) of clean engine oil to the outside diameter of the flywheel locator pin. 4. Apply a small amount (2 to 3 drops) of clean engine oil to the crankshaft seal surface. 5. Inspect the J35621-B flange for imperfections that may damage the crankshaft rear oil seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip surface of the crankshaft rear oil seal. 6. Remove the sleeve from the crankshaft rear oil seal. 7. Apply a small amount (2 to 3 drops) of clean engine oil to the outside diameter of the crankshaft rear oil seal. 8. Install the crankshaft rear oil seal onto the J35621-B. 9. Install the J35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement > Page 2191 Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail. 10. Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing. 10.1. Turn the J35621-B wing nut clockwise until the crankshaft rear oil seal is installed near to flush and square to the crankshaft rear oil seal housing. Increased resistance will be felt when the crankshaft rear oil seal has reached the bottom of the crankshaft rear oil seal housing bore. 10.2. Turn the J35621-B wing nut counterclockwise to release the J35621-B from the crankshaft rear oil seal. 11. Remove the J35621-B from the crankshaft. 12. Wipe off any excess engine oil with a clean rag. 13. Install the engine flywheel. 14. Install the transmission assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement > Page 2192 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Crankshaft Rear Oil Seal Housing Replacement Removal Procedure Important: Do not remove the crankshaft rear oil seal housing if only replacing the crankshaft rear oil seal. 1. Remove the oil pan. 2. Remove the transmission assembly. 3. Remove the engine flywheel. 4. Remove the bolts and the nut holding the crankshaft rear oil seal housing to the engine. 5. Remove the crankshaft rear oil seal housing. 6. Remove and discard the crankshaft rear oil seal housing gasket. 7. Clean all the sealing surfaces. 8. Inspect and replace the crankshaft rear oil seal housing for warping, cracks, wear, or damage. Installation Procedure Important: When installing a NEW crankshaft rear oil seal housing the crankshaft rear oil seal will come with the housing. If reusing the housing and then installing a NEW seal follow the instructions for installing the housing and than Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal Replacement > Page 2193 1. Install a NEW crankshaft rear oil seal housing gasket. 2. Install the NEW crankshaft rear oil seal housing with the oil seal to the engine block using the following procedure. Important: Do not oil or grease the seal lip or the crankshaft seal area. 2.1. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a guide to ease the seal lip over the end of the crankshaft. 2.2. Push the crankshaft rear oil seal housing fully onto the crankshaft until the crankshaft rear oil seal housing is against the crankshaft rear oil seal gasket and the engine. 2.3. Remove the sleeve. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts and the nut to the crankshaft rear oil seal housing. Tighten the crankshaft rear oil seal housing bolts and nut to 12 Nm (106 inch lbs.). 4. Install the engine flywheel. Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. 5. Install the transmission assembly. 6. Install the oil pan. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Tools Required J35468 Crankshaft Aligner/Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Use a suitable prying tool to remove the crankshaft front oil seal. 3. Inspect the engine front cover seal bore for damage. 4. Inspect the crankshaft balancer seal area. Installation Procedure 1. Lubricate the exterior of the crankshaft front oil seal with clean engine oil. 2. Use the J35468 with a hammer in order to install the crankshaft front oil seal. 3. Inspect to ensure the crankshaft front oil seal is flush and square to the engine front cover. 4. Install the crankshaft balancer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Customer Interest: > 1539013 > Jul > 04 > Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Valve Guide Seal: Customer Interest Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 1539013 > Jul > 04 > Engine SES Lamp ON/Misfire DTC' Set Towing Uphill Valve Guide Seal: All Technical Service Bulletins Engine - SES Lamp ON/Misfire DTC' Set Towing Uphill Subject: SES Light and P0300 When Towing, Cruising Uphill or on hard Acceleration - kw 4.3, 5.0, 5.7 accelerate cruise cylinderhead DTC L30, L31, L35, LF6, LU3, P0300, P0301, P0302, P0303, P0304, P0305, P0306, P0307 P0308 # PIP3081 - (07/23/2004) Models: The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI. Condition/Concern: The vehicle may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard acceleration and then stop misfiring shortly after returning to an idle. Typically, cylinders 3, 4, 5 or 6 will be the ones to experience this. Recommendation/Instructions: If the P0300 SI diagnostics did not isolate a concern, the following may help: Remove the valve cover, valve springs and valve seals on the effected cylinder or cylinders. A small wire tie or rubber bands can be placed in the valve stem keeper groove to prevent the valve from falling into the cylinder. Rotate the valve while moving it up and down in the guide to see if it binds. If a binding valve is found, remove both cylinder heads and use either of the following methods to increase the stem to guide clearance: ^ Send the head out to a machine shop and advise them to increase the valve stem to guide clearance to 0.002 inch per guide. ^ Hone the guide with a 9 mm hone, such as Snap On BCG249, until a clearance of 0.002 inch is obtained. This will usually take about 4 strokes of the hone. Reassemble the cylinder heads using new valve seals. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Models Affected Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2219 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2220 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2221 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2222 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2223 Left Side Control Valve Body Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2224 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2225 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2226 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 2231 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2236 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2237 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2238 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2248 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2249 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2250 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2251 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2252 Left Side Control Valve Body Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2253 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2254 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 2255 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 2260 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2265 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2266 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Guide Seal: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 2267 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 2268 Valve Guide Seal: Specifications Valve Stem Clearance - Intake Production ................................................................................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Service ......................................................................................................................................................... 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Clearance - Exhaust Production ................................................................................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch) Service ......................................................................................................................................................... 0.025 - 0.094 mm (0.0010 - 0.0037 inch) Oil Seal Installed Height ............................................................................................................................................. 1 - 2 mm (0.03937 - 0.07874 inch) (Measured from the Top of the Large Diameter Valve Guide Bevel to the Bottom of the Valve Stem Oil Seal) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 2269 Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required J22794 Spark Plug Port Adapter - J38606 Valve Spring Compressor - J5892-D Valve Spring Compressor Removal Procedure 1. Remove the valve rocker arm cover. 2. Remove the required valve rocker arms. 3. Remove the required spark plugs. 4. Install the J22794 into the spark plug hole. 5. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 6. Remove a bolt from a valve rocker arm. 7. Install a flat washer on the bolt. 8. Install the bolt in the valve rocker arm bolt hole for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 9. Use the J5892-D in order to compress the valve spring. 9.1. Hook the slotted end of J5892-D under the washer on the valve rocker arm bolt. 9.2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Notice: Completely engage the J38606 jaws on the valve spring. The J38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 2270 10. Use J38606 when J5892-D will not fit. 11. Remove the valve keys (1). 12. Carefully release the valve spring tension. 13. Remove the J5892-D or J38606 14. Remove the valve spring cap (2) and valve spring (3). 15. Remove the valve stem oil seal (4). Installation Procedure 1. Install the valve seals (4). 2. Install the valve spring (3). 3. Install the valve spring cap (2) on the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 2271 by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 4. To press the valve spring (3) use the J5892-D. Notice: Completely engage the J38606 jaws on the valve spring. The J38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 5. Use the J38606 if the clearance does not permit use of the J5892-D. 6. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 7. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 8. Remove the J5892-D or the J38606. 8.1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 8.2. Tap the end of the valve stem with a plastic faced hammer in to seat the valve stem keys, if necessary. 9. Remove the J22794. 10. Install the spark plugs. 11. Install the valve rocker arms to the cylinder head. 12. Install the valve rocker arm cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 2279 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications > Page 2280 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Engine - Balance Shaft Rattling Noises (Cancellation) Balance Shaft: Technical Service Bulletins Engine - Balance Shaft Rattling Noises (Cancellation) Bulletin No.: 00-06-01-023C Date: August 30, 2006 TECHNICAL Subject: Engine/Balance Shaft "Rattle" Noise Models: 1992-2003 Chevrolet and GMC C/K, S/T, M/L, G and P Models 1992-2001 Oldsmobile Bravada with 4.3 L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to cancel this bulletin. Please discard Corporate Bulletin Number 00-06-01-023B (Section 06 -- Engine/Propulsion System). Technicians should refer to Corporate Bulletin Number 03-06-01-024C for information on engine/balance shaft "rattle" noise concerns. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Page 2286 Balance Shaft: Specifications Balance Shaft Driven Gear Bolt Torque: First Pass ............................................................................................................................................. .......................................................... 15 ft. lbs. Final Pass ................................................................. ................................................................................................................................... 35 degrees Balance Shaft Retainer Bolt ................................................................................................................ ............................................................ 106 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Technical Service Bulletins > Page 2287 Balance Shaft: Service and Repair Balance Shaft Replacement Removal Procedure 1. Remove the radiator. 2. Remove the A/C condenser, if equipped. 3. Remove the valve lifter pushrod guide. 4. Remove the camshaft timing chain and sprockets. Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 5. Remove the balance shaft. 6. Clean and inspect the balance shaft. Installation Procedure 1. Install the balance shaft. 2. Install the camshaft timing chain and the camshaft sprocket. 3. Install the crankshaft position reluctor ring and the engine front cover. 4. Install the valve lifter pushrod guide. 5. Install the A/C condenser, if equipped. 6. Install the radiator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Balance Shaft Bearing Rear Bearing Journal Clearance .......................................................................................................................... 0.050 - 0.088 mm (0.0020-0.0035 inch) Rear Bearing Journal Diameter ....................................................................................................................... 38.085 - 38.100 mm (1.4994 - 1.500 inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Bearing > Component Information > Specifications > Page 2291 Balance Shaft Bearing: Service and Repair Balance Shaft Bearing and/or Bushing Replacement Removal Procedure Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 1. Remove the balance shaft. 2. Remove the balance shaft rear bearing. Installation Procedure 1. Install the balance shaft rear bearing. 2. Install the balance shaft. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2295 Camshaft Gear/Sprocket: Service and Repair Timing Chain and Sprockets Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. 5. Remove the timing chain and sprockets. 6. Clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the timing chain and the sprockets. 2. Remove the bolt from the crankshaft. Notice: Do not reuse the engine front cover. Oil leaks may result. 3. Install the engine front cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Notice: In order to rotate the engine install a bolt with the same threads as the crankshaft, but do not use the crankshaft balancer bolt or a bolt longer than 1 inch, in the crankshaft. Failing to do so will cause damage to the bolt threads and the crankshaft threaded hole when removing the bolt. 3. Install a 7/16-20 x 1 inch bolt into the end of the crankshaft. Notice: Align the timing marks before removing the timing chain. If it is necessary to turn either the camshaft or the crankshaft with the timing chain removed, loosen or remove the valve rocker arms. Turning either the crankshaft or camshaft with the timing chain removed may cause the pistons to contact the valves, resulting in damage. 4. Rotate the crankshaft until: 4.1. The timing marks on both sprockets line up. 4.2. The number four cylinder is at Top Dead Center (TDC) of the compression stroke. 5. Remove the timing chain and sprockets. 6. Clean and inspect the timing chain and sprockets. Installation Procedure 1. Install the timing chain and the sprockets. 2. Remove the bolt from the crankshaft. Notice: Do not reuse the engine front cover. Oil leaks may result. 3. Install the engine front cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: Customer Interest Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2307 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2308 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2309 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's Timing Chain Tensioner: All Technical Service Bulletins Engine - Engine Rattle at 1,800-2,200 RPM's Bulletin No.: 03-06-01-024C Date: August 30, 2006 TECHNICAL Subject: Rattle Noise In Engine (Install Timing Tensioner Kit) Models: 1996-2003 Chevrolet Astro, Blazer, Express, S-10, Silverado and P Models 1996-2003 GMC Jimmy, Safari, Savana, Sierra, Sonoma 1996-2001 Oldsmobile Bravada with 4.3L V6 Engine (VINs W, X - RPOs L35, LF6, LU3) Supercede: This bulletin is being revised to add additional models. Please discard Corporate Bulletin Number 03-06-01-024B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a rattle-type noise coming from the engine at approximately 1800 to 2200 RPMs. Cause The spark, rattle-type noise may be caused by torsional vibration of the balance shaft. Correction If detonation noise is present, perform detonation/spark knock diagnostics first. Install a new tensioner assembly kit using the procedure below. Remove the engine front cover. Refer to SI for engine front cover removal procedure. Remove the crankshaft sensor reluctor ring and line up the timing marks on the crank gear and cam shaft gear. Remove the camshaft gear and chain. For model years 1996-1998, remove the crankshaft sprocket using J 5825-A. Pull the shipping pin and discard. Remove the nylon timing chain tensioner blade from the timing chain tensioner bracket. Position the bracket on the front of the engine. The upper two attaching holes of the bracket will line up with the center two engine front cover bolt holes. The lower bracket holes will line up with the engine front cover alignment holes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2315 Use a hammer and the J 46165 Pin Driver to install the dowel pins through the two lower holes in the bracket and into the engine block. Make sure that the bracket is held firmly in place before proceeding. For model years 1996-1998, install a roller-type timing chain set. Install the crankshaft sprocket using the J 5590 Crankshaft Gear Installer. Install the timing chain around the crankshaft sprocket and position the timing chain to the driver's side of the engine. Install the nylon timing chain tensioner guide onto the timing chain tensioner bracket pin and position the top of the guide under the tab at the top of the bracket. Install the camshaft sprocket into the chain and then to the camshaft. Install the bolts finger-tight. Make sure the timing marks are aligned, then tighten the camshaft sprocket bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Install the crankshaft reluctor ring. Install the engine front cover and place a washer under the two center cover bolts that extend through the tensioner bracket. These washers are required to maintain the proper crush on the engine front cover seal. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2316 Tighten the bolts to 12 N.m (106 lb in). Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 03-06-01-024C > Aug > 06 > Engine - Engine Rattle at 1,800-2,200 RPM's > Page 2317 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolt Torque ................................................................................................................................................. .......................................................... 106 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2321 Timing Cover: Service and Repair Engine Front Cover Replacement Removal Procedure 1. Remove the engine oil pan. 2. Remove the crankshaft balancer. 3. Remove the water pump. 4. Remove the Crankshaft Position (CKP) sensor. Notice: Do not reuse the engine front cover. Oil leaks may result. 5. Remove the engine front cover. 6. Discard the engine front cover. 7. Clean all sealing surfaces. Installation Procedure Notice: Do not reuse the engine front cover. Oil leaks may result. 1. Install the engine front cover. 2. Install the engine oil pan. Important: Do not reuse the original seal (O-ring) when installing the crankshaft position sensor to the engine front cover. Erratic engine operation may result. 3. Install the CKP sensor. 4. Install the water pump. 5. Install the crankshaft balancer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the Mass Air Flow/Intake Air Temperature ( MAF/IAT) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2342 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2348 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2349 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2355 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2356 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: ^ Tearing ^ Piercing ^ Arcing ^ Carbon tracking ^ Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 2361 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 2362 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2371 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2372 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2378 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 2379 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 4. Remove the 2 screws from the rotor. 5. Remove the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2382 6. Note the locating holes that the rotor was removed from: ^ The rotor screw holes (1) ^ The rotor locator pin holes (2) 7. Line up the square-cut hole in the vane wheel with the CMP sensor. 8. Remove the 2 screws that hold the camshaft position (CMP) sensor. 9. Discard the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2383 10. Remove the CMP sensor. 11. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Support the distributor drive gear in a V-block or similar fixture. 13. Drive out the roll pin with a suitable punch. 14. Remove the driven gear from the distributor shaft. 15. Remove the round washer. 16. Remove the tang washer. 17. Remove the shim washer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2384 18. Remove the old oil seal. ASSEMBLY PROCEDURE IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. 2. Insert the sensor into the housing. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2385 3. Install two new screws for the camshaft position (CMP) sensor. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identity the correct rotor mounting position: ^ At the rotor screw holes (1) ^ At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2386 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 14. Support the distributor drive gear in a V-block or similar fixture. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2387 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2388 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: ^ The intake manifold ^ The cylinder head ^ The camshaft ^ The timing chain or sprockets ^ The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. ^ Twist each spark plug 1/2 turn. ^ Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2389 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2390 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). ^ If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. ^ In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2391 NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2392 13. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 15. Install the engine cover. INSTALLATION PROCEDURE 2 IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2393 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). ^ The alignment will not be exact. ^ If the driven gear is installed incorrectly, the dimple Will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. 4. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2394 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2395 8. Install the distributor cap. 9. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 13. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 14. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 2396 Distributor: Service and Repair Distributor Inspection 1. Remove the engine cover. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Ignition System Specifications Spark Plug Torque 15 N.m Spark Plug Gap 1.52 mm Spark Plug Type R41-932 [AC plug type] Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2400 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................ R41-932 (AC plug type) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling - Colder plug ^ Pre-ignition causing spark plug and/or engine damage - Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2403 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2404 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 2405 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed Specification Spark plug gap: 1.524 mm (0.060 in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection Normal The compression builds up quickly and evenly to the specified compression. Leaking The compression is low on the first compression stroke. The compression builds up with the following strokes, but does not reach the specified compression. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt Torque ................................................................................................................................................. ................................................................ 33 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2412 Water Pump: Service and Repair Water Pump Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant from the radiator. 2. Remove the air cleaner assembly. 3. Remove the Mass Air Flow (MAP) sensor. 4. Remove the upper fan shroud. 5. Remove the drive belt. 6. Remove the fan and fan blade clutch assembly. 7. Remove the coolant pump pulley bolts and the pulley. 8. Disconnect the coolant bypass hose and clamps. 9. Disconnect the radiator outlet hose from the coolant pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2413 10. Remove the four coolant pump bolts. 11. Remove the coolant pump. 12. Remove the gaskets. Important: Make sure all of the gasket mating surfaces are free of burrs or other imperfections. 13. Inspect all of the parts. Replace the parts as necessary. Installation Procedure 1. Install the coolant pump gaskets. 2. Install the coolant pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts retaining the coolant pump. Tighten the bolts to 45 Nm (33 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2414 4. Connect the coolant bypass hose and clamps. 5. Connect the radiator outlet hose to the coolant pump. 6. Install the coolant pump pulley and the bolts. Tighten the coolant pump pulley bolts to 25 Nm (18 ft. lbs.). 7. Install the fan and fan blade clutch assembly. 8. Install the drive belt. 9. Install the upper fan shroud and the bolts. 10. Install the Mass Air Flow (MAF) sensor. 11. Install the air cleaner assembly. 12. Refill the radiator with coolant. 13. Start engine. After engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2420 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2421 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2422 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2423 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity w/ C36 (Rear Heater) .......................................................................................................................... .................................................................. 16.5 qts. w/o C36 (Rear Heater) ....................................... ................................................................................................................................................... 13.5 qts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2426 Coolant: Fluid Type Specifications Coolant Type .................................................................................................... Use only GM Goodwrench(R) Dex-Cool(R) in a 50/50 mixture with clean water. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine Block Coolant Drain Hole Plug Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Oil Cooler Pipe Bracket Bolt to Oil Pan Torque ................................................................................................................................................. ............................................................ 89 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Specifications Coolant Outlet: Specifications Water Outlet Stud Torque ................................................................................................................................................. ................................................................ 18 ft. lbs. Coolant Outlet Bolt/Stud Torque ................................................................................................................................................. ................................................. 25 Nm (18 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Removal Procedure 1. Disconnect the coolant recovery reservoir hose from the from the radiator filler neck. 2. Remove the two reservoir retainers. 3. Disconnect the electrical connectors from the washer pumps. 4. Disconnect the washer hose(s) from the washer pump(s) 5. Remove the coolant recovery reservoir/windshield washer assembly. 6. Drain the coolant in the reservoir. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 2439 Installation Procedure 1. Connect the electrical connector(s) to the washer pump(s) 2. Connect the washer hose(s) to the washer pump(s). 3. Install the coolant recovery reservoir. 4. Install the retainers. 5. Install the coolant recovery reservoir hose. 6. Refill the coolant recovery reservoir with coolant to the proper level. Use the proper fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications Cooling Fan Blade to Fan Clutch Bolts Torque ................................................................................................................................................. ................................................. 33 Nm (24 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis Fan Clutch: Technical Service Bulletins A/T - Intermittent Downshift/Slip/Cycling Diagnosis File In Section: 07 Transmission/Transaxle Bulletin No.: 99-07-30-016B Date: October, 2002 INFORMATION Subject: Diagnostic Information For Intermittent Transmission Downshift, Slip, Busy/cycling TCC or Noisy Cooling Fan Models: 1999-2000 Cadillac Escalade 2002-2003 Cadillac Escalade, Escalade EXT 1988-2003 Chevrolet Astro, Blazer, S-10, Silverado, Suburban 1989-2003 Chevrolet/Geo Tracker 1995-2003 Chevrolet Tahoe 1996-2003 Chevrolet Express 1988-1994 GMC S-15 1988-1999 GMC Suburban 1988-2003 GMC Safari, Sierra 1995-2003 GMC Sonoma, Yukon, Yukon XL 1996-2003 GMC Savana 1999-2001 GMC Envoy 1991-2001 Oldsmobile Bravada 2003 HUMMER H2 with Air Conditioning This bulletin is being revised to change the Model information and text. Please discard Corporate Bulletin Number 99-07-30-016A (Section 07 - Transmission/Transaxle) Some customers may comment that at times the transmission seems to slip, or that there is a loud roar from the engine with slow acceleration. This condition is most noticeable after the vehicle has sat idle for 12 or more hours, or on hot days when the A/C is on and the vehicle moves slowly with traffic. Typical comments from customers may include the following conditions: ^ Intermittent slipping ^ Intermittent downshift followed by an upshift, both with no apparent reason ^ Busyness or cycling of the TCC (torque converter clutch) at steady throttle conditions and on a level roadway ^ Noisy cooling fan The type of concern described above requires further definition. The customer should be asked the following questions: ^ Is the situation more pronounced with higher vehicle loads such as when pulling a trailer? ^ Do warmer ambient temperatures make the situation more pronounced? ^ When the condition occurred, did you have the A/C on, and were you driving in stop and go city traffic? ^ Does the condition exhibit itself on the first start-up after sitting more than eight hours? If the customer indicates that these conditions apply, and your observation confirms that the vehicle is operating properly, provide the customer with the vehicle operating description included at the end of this bulletin. Further action may not be necessary. A service procedure follows if further definition is required. Diagnostic Aids Cooling fan operation or the resulting sound varies. The cooling fan clutch may be described as a continuously variable clutch. If the vehicle engine is running, the fan blade is always turning unless the fan clutch is non-functional. The speed of the fan in relation to engine speed is temperature dependent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 2448 Maximum fan speed (air flow and related fan noise) through the engine compartment is experienced under two conditions. 1. When the vehicle sits in an unused condition for several hours, the viscous fluid within the thermostatic fan clutch assembly migrates and fully engages the clutch of the fan. After a short drive, the viscous fluid will migrate to the storage area in the fan clutch and the fan clutch will slip, reducing the noise (roar of the fan). This is normal thermostatic fan clutch operation. 2. When the engine is running, and the air being drawn by the fan or pushed through the radiator from the vehicle movement reaches a high enough temperature, the fan clutch will fully engage the fan clutch, drawing additional air through the radiator to lower the engine coolant temperature and A/C refrigerant temperature. When the cooling fan clutch fully engages, fan noise increases (for example; this is the same as switching an electric household fan from low to high speed). Some customers have interpreted this sound increase to be an increase in the engine RPM due to transmission downshift, transmission slipping, or TCC cycling. As the engine coolant temperature decreases, the fan clutch will begin to slip, lowering the actual speed of the fan blade and the resultant sound. Service Procedure When diagnosing an intermittent transmission downshift, slip, or busy/cycling TCC, follow these steps: 1. Verify the transmission fluid level and the fluid condition. Refer to the Automatic Transmission sub-section of the appropriate Service Manual. 2. Test drive the vehicle under the conditions described by the customer (ambient temperature, engine coolant temperature, trailering, etc.). It may be necessary to partially restrict airflow to the radiator in order to raise the engine coolant temperature to match the customer's conditions. 3. Monitor the engine RPM and the engine coolant temperature using a scan tool. 4. Listen for an actual increase in the engine RPM. Use either the vehicle tachometer (if equipped), the Tech 2 RPM or transmission slip speed as an indicator, rather than just the sound. If the engine RPM display on the tachometer or the Tech 2 increases, verify the scan tool RPM and coolant temperature readings. If the noise increase is due to the engagement of the fan, the engine RPM will not increase and the engine coolant temperature will begin to decrease after the fan engages. As the fan runs, the engine coolant temperature will drop and the fan will disengage, reducing noise levels. The engine RPM will not decrease. This cycle will repeat as the engine coolant temperature rises again. If the above procedure shows the condition to be cooling fan-related, no further action is necessary. The vehicle should be returned to the customer and the condition explained. If the above procedure shows the condition to be other than cooling fan-related, refer to the Automatic Transmission sub-section of the appropriate Service Manual for transmission diagnosis information. The following information regarding the operation of the engine cooling fan should be photocopied and given to the customer. Intermittent Transmission Downshift All light duty trucks are equipped with a thermostatic engine cooling fan. This fan is designed to provide greater fuel efficiency and quieter operation than a standard fan. These benefits are possible through the addition of a thermostatic clutch to the fan drive. When the engine is cool (it the engine has been run in the last few hours), the clutch allows the fan to "slip" or turn at a speed slower than the engine. By turning at a slower speed, the fan uses less horsepower, which saves fuel, and is quieter. When the engine temperature reaches a preset temperature or if the engine has not been run for several hours, the fan "engages" and turns at the same speed as the engine. "Engagement" of the fan provides increased airflow through the radiator to cool the engine. As the airflow increases, fan operation becomes clearly audible. This increase in noise can easily be mistaken for an increase in engine RPM and may be incorrectly blamed on the automatic transmission. When operating an unloaded vehicle in cooler ambient temperatures, the thermostatic clutch usually won't fully engage. However, if the vehicle is pulling a trailer, is heavily loaded or is operated at high ambient temperatures, the thermostatic fan clutch may cycle on and off as the engine coolant temperature rises and falls. The sound of fan operation under the conditions described above is a sign that the cooling system on your vehicle is working correctly. Replacement or modification of the cooling system or the transmission parts will not change or reduce the noise level. Attempts to reduce this noise may cause you, the customer, to believe that your vehicle is not reliable and will inconvenience you by causing your vehicle to be out of service. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > A/T - Intermittent Downshift/Slip/Cycling Diagnosis > Page 2449 DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 2450 Fan Clutch: Specifications Cooling Fan Clutch to Water Pump Bolts Torque ................................................................................................................................................. ................................................. 56 Nm (41 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine Compartment Fan > Component Information > Service and Repair Engine Compartment Fan: Service and Repair Fan Replacement Tools Required J41240 Fan Clutch Wrench Removal Procedure Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced. 1. Remove the upper fan shroud. 2. Remove the fan clutch using the J41240. 3. Remove the fan and fan blade clutch assembly from the vehicle. 4. Remove the four bolts retaining the fan blade to the fan blade clutch. 5. Remove the fan from the fan blade clutch. Installation Procedure 1. Install the fan to the fan blade clutch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four bolts retaining the fan blade to the clutch. Tighten the bolts to 33 Nm (24 ft. lbs.). 3. Install the fan blade clutch assembly using the J41240. Tighten the fan blade clutch assembly to 56 Nm (41 ft. lbs.). 4. Install the upper fan shroud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2458 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2459 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2460 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2461 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Upper Fan Shroud Bolts Torque ................................................................................................................................................. ................................................. 15 Nm (11 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud Replacement - Upper Fan Shroud: Service and Repair Fan Shroud Replacement - Upper Fan Shroud Replacement - Upper Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the upper fan shroud bolts. 3. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper shroud bolts. Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the air cleaner assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Fan Shroud Replacement - Upper > Page 2467 Fan Shroud: Service and Repair Fan Shroud Replacement - Lower Fan Shroud Replacement - Lower Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the upper fan shroud bolts. 3. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper shroud bolts. Tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the air cleaner assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Diagrams Coolant Bypass Valve Solenoid - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Front) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. Refer to Draining and Filling Cooling System 4. Remove the heater inlet pipe (5) and the outlet pipe (6) from the bypass valves (4). 5. Remove the bolt (3) that retains the valve (4) to the heater assembly. 6. Remove the bypass valve (4) from the heater assembly. INSTALLATION PROCEDURE 1. Install the bypass valve (4) to the heater assembly. NOTE: Refer to Fastener Notice 2. Install the bolt (3) that retains the valve (4) to the heater assembly. Tighten Tighten the bolt to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 2473 3. Install the heater inlet pipe (5) and the outlet pipe (6) to the bypass valves. 4. Refill the cooling system. Refer to Draining and Filling Cooling System 5. Install the upper fan shroud. 6. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 2474 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Rear) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. Refer to Draining and Filling Cooling System 4. Disconnect the electrical connector from the valve. 5. Disconnect the vacuum hose from the valve. 6. Remove the hose clamps from the outlet pipe (8) and from the inlet pipe (4). 7. Remove the bolt (3) that retains the valve to the heater assembly. 8. Remove the bypass valve (5) from the heater assembly. 9. Remove the heater hoses from the engine to the hot water bypass valve. INSTALLATION PROCEDURE 1. Install the heater hoses to the engine to the hot water bypass valve. 2. Install the bypass valve (5) to the heater assembly. NOTE: Refer to Fastener Notice. 3. Install the bolt (3) that retains the valve (5) to the heater assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 2475 Tighten Tighten the bolt to 4 N.m (35 lb in). 4. Install the heater inlet pipe (4) and the outlet pipe to the bypass valves. 5. Connect the vacuum hose to the valve. 6. Connect the electrical connector to the valve. 7. Refill the cooling system. Refer to Draining and Filling Cooling System 8. Install the upper fan shroud. 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2480 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2481 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CASE REPLACEMENT (C60) REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Remove the heater hoses from the heater core. 4. Remove the evaporator case from the vehicle. 5. Remove the heater case retaining nuts (2) from the engine compartment. 6. Roll out the instrument panel. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. 7. Disconnect the electrical connectors. 8. Disconnect the vacuum lines. 9. Remove the heater case (5) from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2484 1. Install the heater case (5) to the vehicle. 2. Connect the vacuum lines. 3. Connect the electrical connectors. 4. Roll the instrument panel upward. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the heater case retaining nuts (2) to the engine compartment. Tighten Tighten the nuts to 6 N.m (53 lb in). 6. Install the evaporator casing to the vehicle. 7. Connect the heater hoses from the heater core. 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2485 Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the heater hoses. 3. Remove the screws (9) that retain the cover to the heater case assembly. 4. Remove the straps (8) that retain the heater core to the heater case assembly. 5. Remove the heater core (7) from the vehicle. INSTALLATION PROCEDURE 1. Install the heater core to the vehicle. 2. Install the straps that retain the heater core to the heater case assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the heater core to the heater case assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the heater hoses. 5. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2486 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the body side front lower trim panel. 3. Remove the clamps from the auxiliary heater pipes. 4. Disconnect the auxiliary heater pipes from the auxiliary heater module. 5. Remove the screws and the band clamp from the right side of the heater core. 6. Remove the screw and the band clamp from the left side of the heater core. IMPORTANT: Before removing the auxiliary heater module from the vehicle, be sure to place a protective cover on the floor in order to prevent coolant from leaking onto the carpet. 7. Remove the heater core from the heater core case. 8. Remove the seals from the heater core. INSTALLATION PROCEDURE 1. Install the seals to the heater core. 2. Install the heater core into the heater core case. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw and the band clamp to the left side of the heater core. Tighten Tighten the screws and the band clamp to 2 N.m (18 lb in). 4. Install the screws and the band clamp to the right side of the heater core. Tighten Tighten the screw and the band clamp to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2487 5. Connect the auxiliary heater pipes from the auxiliary heater module. 6. Install the clamps to the auxiliary heater pipes. 7. Install the body side front lower trim panel. 8. Refill the system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolts (3) that retain the front pipes (5) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2492 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2493 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2494 Heater Hose: Service and Repair Heater Hose Replacement - Inlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the inlet (3) hose from the heater core. 7. Disconnect the inlet (3) hose from the water valve. INSTALLATION PROCEDURE 1. Connect the inlet (3) hose to the water valve. 2. Connect the inlet (3) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2495 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fittings component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2496 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the outlet (2) hoses from the heater core. 7. Disconnect the outlet (2) hoses from the water valve. INSTALLATION PROCEDURE 1. Connect the outlet (2) hose to the water valve. 2. Connect the outlet (2) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 2497 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fitting component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2526 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2527 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2528 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2529 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2530 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2532 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2533 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2534 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Diagrams > Page 2535 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the coolant from the radiator. 2. Remove the radiator drain stem and seal. The seal usually comes out attached to the stem. 3. Remove the body of the drain cock. Use your fingers or needle nose pliers to disengage the locking tangs from the side tank. 4. Clean the drain. Installation Procedure 1. Install the drain cock body. Ensure that the body is fully seated in the side tank and that the locking tangs are engaged. 2. Install the seal on the drain cock stem. 3. Install the drain cock. Turn the stem clockwise to lock. 4. Refill the coolant to the proper level. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Specifications Radiator Hose: Specifications Upper Radiator Hose Support Bracket Nut to Exhaust Manifold Stud Torque ................................................................................................................................................. ................................................................ 27 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet Radiator Hose: Service and Repair Radiator Hose Replacement - Inlet Radiator Hose Replacement - Inlet Removal Procedure 1. Drain the coolant from the radiator to a level below the hose being removed. 2. Remove the air cleaner assembly. 3. Reposition the radiator hose clamp. 4. Remove the inlet hose from the radiator. 5. Reposition the clamp from the thermostat housing. 6. Remove the inlet hose from the thermostat housing Installation Procedure 1. Install the inlet hose to the thermostat housing. 2. Reposition the clamp to the thermostat housing. 3. Install the inlet hose to the radiator. 4. Reposition the clamp to the radiator. 5. Install the air cleaner assembly. 6. Fill the coolant to the proper level. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2545 Radiator Hose: Service and Repair Radiator Hose Replacement - Outlet Radiator Hose Replacement - Outlet Removal Procedure 1. Drain the engine coolant. 2. Remove the air cleaner assembly. 3. Reposition the radiator hose clamp. 4. Remove the outlet hose from the radiator. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Reposition the outlet hose clamp from the water pump. 7. Remove the outlet hose from the water pump. Installation Procedure 1. Install the outlet hose to the water pump. 2. Reposition the outlet hose clamp to the water pump. 3. Lower the vehicle. Refer to Vehicle Lifting. 4. Install the outlet hose to radiator. 5. Reposition the radiator hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hose Replacement - Inlet > Page 2546 6. Install the air cleaner assembly. 7. Fill the engine coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2552 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2553 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2554 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2555 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2575 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2576 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2577 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2578 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2579 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Diagrams > Page 2592 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair Thermostat Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant to a level below the thermostat. 2. Remove the air cleaner assembly. 3. Disconnect the ground lead from the coolant outlet. 4. Remove the Bolt/Stud and the bolt on the coolant outlet. 5. Remove the coolant outlet. 6. Remove the thermostat. 7. Clean all of the parts and the sealing surfaces. Installation Procedure 1. Install the thermostat. 2. Install the coolant outlet. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt and the Bolt/Stud. Tighten the bolt and the Bolt/Stud to 25 Nm (18 ft. lbs.). 4. Install the ground lead to the Bolt/Stud. 5. Install the air cleaner assembly. 6. Refill the coolant. 7. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt Torque ................................................................................................................................................. ................................................................ 33 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2599 Water Pump: Service and Repair Water Pump Replacement Removal Procedure Caution: In order to avoid being burned, do not service the engine while it is still hot. Service the engine when it is cool. 1. Drain the coolant from the radiator. 2. Remove the air cleaner assembly. 3. Remove the Mass Air Flow (MAP) sensor. 4. Remove the upper fan shroud. 5. Remove the drive belt. 6. Remove the fan and fan blade clutch assembly. 7. Remove the coolant pump pulley bolts and the pulley. 8. Disconnect the coolant bypass hose and clamps. 9. Disconnect the radiator outlet hose from the coolant pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2600 10. Remove the four coolant pump bolts. 11. Remove the coolant pump. 12. Remove the gaskets. Important: Make sure all of the gasket mating surfaces are free of burrs or other imperfections. 13. Inspect all of the parts. Replace the parts as necessary. Installation Procedure 1. Install the coolant pump gaskets. 2. Install the coolant pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the four bolts retaining the coolant pump. Tighten the bolts to 45 Nm (33 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2601 4. Connect the coolant bypass hose and clamps. 5. Connect the radiator outlet hose to the coolant pump. 6. Install the coolant pump pulley and the bolts. Tighten the coolant pump pulley bolts to 25 Nm (18 ft. lbs.). 7. Install the fan and fan blade clutch assembly. 8. Install the drive belt. 9. Install the upper fan shroud and the bolts. 10. Install the Mass Air Flow (MAF) sensor. 11. Install the air cleaner assembly. 12. Refill the radiator with coolant. 13. Start engine. After engine reaches normal operating temperature, check for coolant leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic Converter-to-Muffler Nuts Torque ................................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2606 Catalytic Converter: Service and Repair Catalytic Converter Replacement (RWD) Removal Procedure Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the catalytic converter assembly. 3. Remove the 3 oxygen sensor electrical connections and clips. 4. Remove the nuts from the muffler flange bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2607 5. Remove the nuts from the exhaust manifold studs (right side). 6. Disconnect the collars from the exhaust manifold studs (right side). 7. Remove the nuts from the exhaust manifold studs (left side). 8. Disconnect the collars from the exhaust manifold studs (left side). 9. Remove the catalytic converter assembly from the muffler assembly. 10. Remove the catalytic converter assembly from the exhaust manifolds. 11. Lower the front of the catalytic converter assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2608 12. Remove the catalytic converter assembly from the hanger. Notice: Do not damage the oxygen sensors when removing the catalytic converter. 13. Remove the catalytic converter assembly from the vehicle by rotating the assembly over the rear of the transmission crossmember. 14. Remove the 3 oxygen sensors. Installation Procedure When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear. In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps. Important: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed. - When exhaust system service requires removing and replacing an oxygen sensor, refer to the applicable service procedure. - Always use new nuts when installing the exhaust pipe to the exhaust manifold. - Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush. 1. Install the 3 oxygen sensors to the catalytic converter assembly. 2. Install the catalytic converter assembly to the hanger. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2609 3. Install the collars on the catalytic converter assembly to the exhaust manifold studs (left side). 4. Loosely install the nuts onto the exhaust manifold studs (left side). 5. Install the collars on the catalytic converter assembly to the exhaust manifold studs (right side). 6. Loosely install the nuts onto the exhaust manifold studs (right side). 7. Connect the catalytic converter assembly and the gasket to the muffler assembly. 8. Loosely install the nuts. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 2610 9. Tighten the exhaust manifold nuts in proper sequence (1-6). - Tighten the catalytic converter assembly-to-exhaust manifold nuts to 53 Nm (39 ft. lbs.). - Tighten the catalytic converter assembly-to-muffler assembly nuts to 40 Nm (30 ft. lbs.). 10. Install the three oxygen sensor electrical connections and clips. 11. Remove the support from the catalytic converter assembly. 12. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolt/Stud Torque: First Pass ............................................................................................................................................. .......................................................... 11 ft. lbs. Final Pass ................................................................. ..................................................................................................................................... 22 ft. lbs. Exhaust Manifold Surface Flatness: Flange to Flange ................................................................................................................................. 0.25 mm - Maximum (0.010 inch - Maximum) Individual Flange ................................................................................................................................ 0.05 mm Maximum (0.002 inch - Maximum) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left Removal Procedure 1. Remove the engine cover. 2. Disconnect the Engine Coolant Temperature (ECT) sensor. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the left front tire. 5. Remove the left fender wheelhouse extension. 6. Remove the catalytic converter assembly. 7. Remove the spark plug wires from the spark plugs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2616 8. Remove the spark plug wire support bolts. 9. Remove the spark plug wire support with the spark plug wires. 10. Remove the front 4 exhaust manifold bolts through the wheelhouse. 11. Remove the 2 rear exhaust manifold bolts through the engine cover opening. 12. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle. 13. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place. 1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold. 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets. 3. Install the exhaust manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2617 - Tighten the 2 rear exhaust manifold bolts through the engine cover opening. - Tighten the front 4 exhaust manifold bolts through the wheelhouse. 4. Install the spark plug wires to the spark plugs. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spark plug wire support and bolts. Tighten the spark plug wire support bolts to 12 Nm (106 inch lbs.). 6. Install the catalytic converter assembly. 7. Install the fender wheelhouse extension. 8. Install the left front tire. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2618 10. Connect the ECT sensor electrical connector. 11. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2619 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement - Right Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the right front tire. 3. Remove the right fender wheelhouse extension. 4. Disconnect the spark plug wires from the spark plugs. 5. Remove the catalytic converter assembly. 6. Remove the exhaust manifold bolts through the wheelhouse. 7. Remove the exhaust manifold with the exhaust manifold gaskets and the spark plug wire shields from the engine. 8. Clean all gasket surfaces. Installation Procedure Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place. 1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2620 2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets. 3. Install the exhaust manifold. 4. Install the catalytic converter assembly. 5. Install the spark plug wires. 6. Install the fender wheelhouse extension. 7. Install the front tire. 8. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Pipe Exhaust Pipe-to-Manifold Nuts Torque ................................................................................................................................................. ........................................... 53 Nm (39 ft. lbs.) Exhaust Pipe-to-Manifold Studs Torque ................................................................................................................................................. ........................................... 15 Nm (11 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Muffler Hanger Hanger-to-Frame Nuts Torque ................................................................................................................................................. ........................................... 45 Nm (33 ft. lbs.) Hanger-to-Transfer Case Bolts (A4WD) Torque ................................................................................................................................................. ........................................... 55 Nm (41 ft. lbs.) Hanger-to-Transmission Bolts (RWD) Torque ................................................................................................................................................. ........................................... 45 Nm (33 ft. lbs.) Hanger-to-Frame Bolts Torque ................................................................................................................................................. ........................................... 25 Nm (18 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Replacement Removal Procedure Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. Caution: In order to avoid being burned, do not service the exhaust system while it is still hot Service the system when it is cool. An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the muffler assembly. 3. Remove the 3 nuts connecting the muffler assembly to the catalytic converter assembly. 4. To aid in the removal of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM P/N 12345884. Remove the muffler assembly from the front hanger. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2630 5. Remove muffler assembly from the rear hanger. 6. Remove the muffler assembly from the tailpipe hanger. 7. Remove the muffler assembly from the vehicle. Installation Procedure When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear. In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps. Important: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed. - Replace the tailpipe when replacing the muffler. - Always use new nuts when installing the exhaust pipe to the exhaust manifold. - Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush. 1. To aid in the installation of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM PIN 12345884. Install the muffler assembly into the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2631 2. Connect the muffler assembly to the tailpipe hanger. 3. Connect the muffler assembly to the rear hanger. 4. Connect muffler assembly to the front hanger. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2632 5. Install the 3 nuts to connect the muffler assembly to the catalytic converter assembly. Tighten the nuts to 40 Nm (30 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2640 Body Control Module C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2641 Body Control Module C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2642 Body Control Module: Description and Operation The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2645 Body Control Module: Removal and Replacement REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control. Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2646 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2647 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: ^ The Techline Terminal ^ The Scan Tool 9. Perform the body control module programing. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2652 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2653 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2693 Engine Control Module: Description and Operation Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2694 Engine Control Module: Description and Operation Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2695 Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2696 Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2697 Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed, with a brief description of the diagnostic functionality. Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the heated sensors are installed before and after the 3-Way Catalyst (TWC). Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 degrees hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor ( HO2S). A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The (TWC) and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx), the system uses a 3-way catalytic converter. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst heated oxygen sensors. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the 3-way catalytic converter. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2698 Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000 - 3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions. Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the effect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1 - 8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1 - 8. indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2699 sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 - Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential firing order are both misfiring, the first misfiring cylinder will accumulate misfires in its buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to it in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles, knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Three-Way Catalyst Oxygen Storage Capacity Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2700 Three-Way Catalyst Storage Capacity The PCM must monitor the 3-Way Catalyst System (TWC) for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor shows significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during its normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor voltage levels. Misfire Monitor Diagnostic Tests Whenever the sensor activity of the post-catalyst (2) oxygen sensor nears the sensor activity of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original pan, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) sensor ^ The Intake Air Temperature (IAT) sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load (6.0L only) ^ When one set of drive axles loses traction while the other set of drive axles are not moving (4WD only and in 4WD low) ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2701 cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. It controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed Sensor (VSS) ^ Mass Air Flow (MAF) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Crankshaft Position (CKP) Sensor ^ Knock Sensor (KS) ^ Throttle Position (TP) Sensor ^ Engine Coolant Temperature (ECT) Sensor ^ Camshaft Position (CMP) Sensor ^ Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable Closed Loop fuel control. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 2702 Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) motor ^ The EVAP system ^ The electronic transmission controls ^ The A/C relay, if so equipped ^ The Vehicle Speed Sensor (VSS) output ^ The Malfunction Indicator Lamp (MIL) control ^ The cruise control enable, if so equipped Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information Engine Control Module: Service and Repair Additional Information The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2705 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2706 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the electronic control unit (ECU) location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2707 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL system. ^ HVAC systems ^ Engine cooling fans etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the DLC. 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal - This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI) - This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure - This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2708 connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ The Crankshaft Variation Learn Procedure ^ The Engine Oil Life Reset Procedure ^ The Idle Learn Procedure ^ The Inspection/Maintenance Complete System Set Procedure ^ The Vehicle Theft Deterrent Password Learn Procedure ^ The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. You must program the replacement control module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2709 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: ^ To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed. Removal Procedure NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 1. Disconnect the PCM harness connectors (4). 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2710 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (4) to the PCM (1). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2711 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 2712 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2724 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2725 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2727 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2732 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2733 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2734 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2735 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2736 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2740 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2741 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2742 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2743 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 2755 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2756 Ignition Control Module (ICM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2757 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS The ICM is connected to the PCM by an Ignition Control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2758 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2770 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2788 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2789 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2790 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2791 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2792 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2793 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2794 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2795 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2796 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2797 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2798 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2799 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2800 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 2801 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2816 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2818 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2833 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2834 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2835 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2836 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2837 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2838 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2839 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2840 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2841 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2842 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2843 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2844 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2845 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2846 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2847 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2851 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2852 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2853 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2854 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 2863 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls Engine Runs Rough/MIL ON/DTC's Set > Page 2869 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2870 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2901 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2902 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2903 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2904 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2905 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2906 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2909 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2910 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2911 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2912 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2913 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 2917 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2921 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) Sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1 - 4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2922 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 2923 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2927 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2928 Intake Air Temperature Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2929 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2930 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2968 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2969 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2970 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2974 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2975 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2976 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2977 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2978 1. Install the new MAP sensor grommet on the MAP sensor. 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 2982 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 2983 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors Oxygen Sensor: Description and Operation Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors > Page 3024 Oxygen Sensor: Description and Operation Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3025 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3028 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3029 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3030 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (4) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3031 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3032 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5813695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (1) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3064 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3065 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3066 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3067 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3068 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3069 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3070 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3071 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 3072 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3076 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3077 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3078 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3079 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3080 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3086 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3087 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3088 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3089 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3090 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3091 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3092 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3093 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3094 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3095 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3096 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 Vehicle Speed Sensor (VSS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3156 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3157 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3158 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3159 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3193 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3194 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3195 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3196 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3197 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3198 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 3199 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3207 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3208 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3209 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3210 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3238 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3239 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3240 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3241 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3242 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3243 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3244 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3245 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3246 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3255 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3261 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3262 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3297 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3298 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3301 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3302 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3303 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3304 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3305 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3348 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3349 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3350 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the Mass Air Flow/Intake Air Temperature ( MAF/IAT) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3371 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3377 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3378 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3384 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3385 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: ^ Tearing ^ Piercing ^ Arcing ^ Carbon tracking ^ Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 3390 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 3391 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3400 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3401 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3407 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 3408 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 4. Remove the 2 screws from the rotor. 5. Remove the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3411 6. Note the locating holes that the rotor was removed from: ^ The rotor screw holes (1) ^ The rotor locator pin holes (2) 7. Line up the square-cut hole in the vane wheel with the CMP sensor. 8. Remove the 2 screws that hold the camshaft position (CMP) sensor. 9. Discard the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3412 10. Remove the CMP sensor. 11. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Support the distributor drive gear in a V-block or similar fixture. 13. Drive out the roll pin with a suitable punch. 14. Remove the driven gear from the distributor shaft. 15. Remove the round washer. 16. Remove the tang washer. 17. Remove the shim washer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3413 18. Remove the old oil seal. ASSEMBLY PROCEDURE IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. 2. Insert the sensor into the housing. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3414 3. Install two new screws for the camshaft position (CMP) sensor. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identity the correct rotor mounting position: ^ At the rotor screw holes (1) ^ At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3415 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 14. Support the distributor drive gear in a V-block or similar fixture. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3416 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3417 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: ^ The intake manifold ^ The cylinder head ^ The camshaft ^ The timing chain or sprockets ^ The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. ^ Twist each spark plug 1/2 turn. ^ Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3418 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3419 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). ^ If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. ^ In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3420 NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3421 13. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 15. Install the engine cover. INSTALLATION PROCEDURE 2 IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3422 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). ^ The alignment will not be exact. ^ If the driven gear is installed incorrectly, the dimple Will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. 4. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3423 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3424 8. Install the distributor cap. 9. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 13. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 14. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 3425 Distributor: Service and Repair Distributor Inspection 1. Remove the engine cover. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Ignition System Specifications Spark Plug Torque 15 N.m Spark Plug Gap 1.52 mm Spark Plug Type R41-932 [AC plug type] Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3429 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................ R41-932 (AC plug type) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling - Colder plug ^ Pre-ignition causing spark plug and/or engine damage - Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 3432 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 3433 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 3434 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed Specification Spark plug gap: 1.524 mm (0.060 in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection Normal The compression builds up quickly and evenly to the specified compression. Leaking The compression is low on the first compression stroke. The compression builds up with the following strokes, but does not reach the specified compression. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3476 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3477 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3478 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3479 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3483 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3484 Intake Air Temperature Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3485 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3486 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3491 Body Control Module C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3492 Body Control Module C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3493 Body Control Module: Description and Operation The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3496 Body Control Module: Removal and Replacement REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control. Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3497 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3498 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: ^ The Techline Terminal ^ The Scan Tool 9. Perform the body control module programing. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3508 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3509 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3528 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3529 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3536 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3537 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3538 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3539 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3540 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3541 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3542 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3543 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3544 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3548 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3549 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3550 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3551 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3560 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 3566 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3567 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3586 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3587 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3602 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3603 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3606 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3607 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3608 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3609 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3610 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Timing Ring > Component Information > Service and Repair Crankshaft Position Timing Ring: Service and Repair Crankshaft Position (CKP) Reluctor Ring Replacement Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position sensor reluctor ring. Installation Procedure Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face towards the engine front cover. 1. Install the crankshaft position sensor reluctor ring. 2. Install the engine front cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3617 Data Link Connector (DLC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3622 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3623 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3646 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3647 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3648 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3649 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3650 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3651 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3652 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3653 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3654 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3655 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3656 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3657 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3658 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3663 Engine Control Module: Description and Operation Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3664 Engine Control Module: Description and Operation Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3665 Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3666 Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3667 Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed, with a brief description of the diagnostic functionality. Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the heated sensors are installed before and after the 3-Way Catalyst (TWC). Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 degrees hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor ( HO2S). A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The (TWC) and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx), the system uses a 3-way catalytic converter. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst heated oxygen sensors. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the 3-way catalytic converter. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3668 Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000 - 3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions. Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the effect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1 - 8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1 - 8. indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3669 sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 - Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential firing order are both misfiring, the first misfiring cylinder will accumulate misfires in its buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to it in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles, knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Three-Way Catalyst Oxygen Storage Capacity Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3670 Three-Way Catalyst Storage Capacity The PCM must monitor the 3-Way Catalyst System (TWC) for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor shows significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during its normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor voltage levels. Misfire Monitor Diagnostic Tests Whenever the sensor activity of the post-catalyst (2) oxygen sensor nears the sensor activity of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original pan, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) sensor ^ The Intake Air Temperature (IAT) sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load (6.0L only) ^ When one set of drive axles loses traction while the other set of drive axles are not moving (4WD only and in 4WD low) ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3671 cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. It controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed Sensor (VSS) ^ Mass Air Flow (MAF) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Crankshaft Position (CKP) Sensor ^ Knock Sensor (KS) ^ Throttle Position (TP) Sensor ^ Engine Coolant Temperature (ECT) Sensor ^ Camshaft Position (CMP) Sensor ^ Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable Closed Loop fuel control. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3672 Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) motor ^ The EVAP system ^ The electronic transmission controls ^ The A/C relay, if so equipped ^ The Vehicle Speed Sensor (VSS) output ^ The Malfunction Indicator Lamp (MIL) control ^ The cruise control enable, if so equipped Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information Engine Control Module: Service and Repair Additional Information The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3675 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3676 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the electronic control unit (ECU) location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3677 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL system. ^ HVAC systems ^ Engine cooling fans etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the DLC. 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal - This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI) - This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure - This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3678 connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ The Crankshaft Variation Learn Procedure ^ The Engine Oil Life Reset Procedure ^ The Idle Learn Procedure ^ The Inspection/Maintenance Complete System Set Procedure ^ The Vehicle Theft Deterrent Password Learn Procedure ^ The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. You must program the replacement control module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3679 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: ^ To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed. Removal Procedure NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 1. Disconnect the PCM harness connectors (4). 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3680 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (4) to the PCM (1). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3681 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3682 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3686 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3690 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) Sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1 - 4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3691 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 3692 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3696 Idle Air Control (IAC) Valve Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3697 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The valve consists of a movable pintle, driven by a gear attached to a two phase bi-polar permanent magnet electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has two separate windings that are called coils. Each coil is fed by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) may set. DIAGNOSTIC AIDS Inspect for the following conditions: ^ A skewed high throttle position (TP) sensor ^ Restricted air intake system ^ Objects blocking the IAC passage or throttle bore ^ The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve ^ Proper operation and installation of all air intake components ^ Proper installation and operation of the mass air flow (MAF) sensor, if equipped ^ A tampered with or damaged throttle stop screw ^ A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped ^ Excessive deposits in the IAC passage or on the IAC pintle ^ Excessive deposits in the throttle bore or on the throttle plate ^ Vacuum leaks ^ Excessive load on engine i.e. transmission, power steering, alternator, etc. ^ A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms-Computers and Controls Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures ^ A low or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms-Computers and Controls Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures ^ If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3698 Steps 1-6 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3699 Steps 7-11 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3700 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC counts are incrementing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3701 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the harness connector from the idle air control (IAC) valve. 4. Remove the IAC valve attaching fasteners. NOTE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 5. Remove the IAC valve assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3702 6. Remove the O-ring. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. ^ Use a carburetor cleaner and a parts cleaning brush in order to remove any carbon deposits. Follow the instructions on the container. ^ Do not use a cleaner that contains methyl ethyl ketone. MEK is an extremely strong solvent and not necessary for this type of deposit ^ Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. ^ If the air passage has heavy deposits, remove the throttle body for a complete cleaning. 2. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if damaged. INSTALLATION PROCEDURE IMPORTANT: If you are installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. 1. Measure the distance between tip of the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Install the IAC valve assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Locations > Page 3703 4. Install the attaching fasteners. Tighten Tighten the IAC valve fasteners to 3 N.m (27 lb in). 5. Connect the IAC harness connector. 6. Install the engine cover. 7. Reset the IAC valve pintle position. IAC VALVE RESET PROCEDURE 1. Turn ON the ignition for 5 seconds, leaving the engine OFF. 2. Turn OFF the ignition for 10 seconds. 3. Start the engine. 4. Check for the proper idle speed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Page 3707 Data Link Connector (DLC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Data Link Communications Information Bus: Description and Operation Data Link Communications DATA LINK COMMUNICATIONS CIRCUIT DESCRIPTION AND OPERATION The Class 2 serial data link allows specified modules to transmit, receive, or exchange data: ^ Transfer Case Shift Control Module (TCSCM) ^ Electronic Brake Control Module (EBCM) ^ Powertrain Control Module (PCM) ^ Body Control Module (BCM) ^ Instrument Panel Cluster (IPC) ^ Driver Information Center (DIC) ^ Inflatable Restraint Sensing And Diagnostic Module (SDM) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the class 2 serial data circuit about once every 2 seconds. When the module detects the class 2 serial data circuit shorted, the setting of all other class 2 serial communication DTCs is inhibited and a U1300, U1301, or a U1305 DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Data Link Communications > Page 3710 Information Bus: Description and Operation General Description DATA LINK COMMUNICATIONS CIRCUIT DESCRIPTION AND OPERATION The Class 2 serial data link allows specified modules to transmit, receive, or exchange data: ^ Transfer Case Shift Control Module (TCSCM) ^ Electronic Brake Control Module (EBCM) ^ Powertrain Control Module (PCM) ^ Body Control Module (BCM) ^ Instrument Panel Cluster (IPC) ^ Driver Information Center (DIC) ^ Inflatable Restraint Sensing And Diagnostic Module (SDM) CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the class 2 serial data circuit about once every 2 seconds. When the module detects the class 2 serial data circuit shorted, the setting of all other class 2 serial communication DTCs is inhibited and a U1300, U1301, or a U1305 DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Begin the diagnosis of the Data Link Communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications when a communication malfunction is present. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3713 Information Bus: Reading and Clearing Diagnostic Trouble Codes With Diagnostic Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Diagnostic Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. With Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Diagnostic Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3714 Information Bus: Symptom Related Diagnostic Procedures A Symptoms - Data Link Communications IMPORTANT: The following steps must be completed before using the symptom tables: 1. Perform the Diagnostic System Check for the subsystem exhibiting the symptoms. The subsystem diagnostic system check will identity where to begin diagnosis of the data link communication system. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices that could affect the operation of the serial data communications systems. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible systems or visible system components for obvious damage or conditions that could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Scan Tool Does Not Power Up ^ Scan Tool Does Not Communicate with Class 2 Device Scan Tool Does Not Communicate With Class 2 Device CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DTCs may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS ^ The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must be connected to the DLC for any other module to communicate with the scan tool. ^ When the class 2 serial data circuit: ^ is shorted to ground ^ is shorted to voltage The following DTCs may set: ^ U1300 ^ U1301 ^ U1305 TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3715 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3716 Steps 10-13 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3717 Steps 14-18 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3718 Steps 19-25 The numbers below refer to the step numbers on the diagnostic table. 2. A partial loss of communication in the class 2 serial data circuit uses a different procedure than a total loss of communication of the class 2 serial data circuit. 4. The following DTCs may be retrieved with a history status. These DTCs are not the cause of the present condition. ^ U1300 ^ U1301 ^ U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 with a current status. This indicates that the malfunction occurred when the ignition was on. 10. Normal class 2 serial data communication cannot take place until the power mode master (PMM) module sends the appropriate power mode message. If the PMM does not send a wake-up message, other modules on the class 2 serial data circuit may not communicate. 12. Disconnecting the splice pack(s) and/or class 2 circuits one at a time and attempting to communicate with any module still connected to the class 2 serial data circuit, will determine whether or not the concern is in the splice pack portion of the class 2 serial data circuit. 13. Connecting the class 2 serial data circuits to the suspect splice pack one at a time while attempting to communicate with any module still connected to the class 2 serial data circuit, will determine which circuit or module on the splice pack is causing the concern. 14. Splitting the class 2 serial data circuit will help isolate the location of the malfunction. If communication can be established, the concern is located in the wiring or one of the modules that is no longer connected to the DLC. If communication cannot be established, the concern is located in the wiring or one of the modules that is still connected to the DLC. 22. If there are no current DTCs that begin with the letter "U", the communication concern has been repaired. 23. The communication concern may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: ^ Scan tool power battery positive voltage at terminal 16. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3719 ^ Scan tool power ground at terminal 4. ^ Common signal ground at terminal 5. The scan tool will power up with the ignition off. Some modules however, will not communicate unless the ignition is on and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Steps 1-4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3725 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3726 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3727 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3728 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3731 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3732 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3733 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3734 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3735 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3736 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3737 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3738 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3739 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3740 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3757 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3758 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3759 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The numbers below refer to the step numbers on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3764 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 3765 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3769 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3770 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3771 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3772 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3773 1. Install the new MAP sensor grommet on the MAP sensor. 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 3777 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 3778 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors Oxygen Sensor: Description and Operation Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors > Page 3819 Oxygen Sensor: Description and Operation Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3820 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3823 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3824 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3825 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (4) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3826 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 3827 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5813695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (1) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3833 Body Control Module C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3834 Body Control Module C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3835 Body Control Module: Description and Operation The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3838 Body Control Module: Removal and Replacement REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control. Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3839 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3840 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: ^ The Techline Terminal ^ The Scan Tool 9. Perform the body control module programing. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3845 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3846 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Engine Control Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Engine Control Module: Connector Views Powertrain Control Module (PCM) C1 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Powertrain Control Module (PCM) C1 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3886 Engine Control Module: Description and Operation Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3887 Engine Control Module: Description and Operation Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3888 Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3889 Engine Control Module: Description and Operation General Information The Powertrain Control Module (PCM) is designed to maintain exhaust emission levels while maintaining excellent driveability and fuel efficiency. The PCM controls the following operations: ^ The fuel control ^ The Ignition Control (IC) ^ The Knock Sensor (KS) system ^ The automatic transmission shift functions ^ The manual transmission ^ The cruise control enable, if so equipped ^ The generator ^ The Evaporative Emissions (EVAP) purge ^ The A/C clutch control, if so equipped ^ The Secondary Air Injection (AIR), if so equipped ^ The Exhaust Gas Recirculation (EGR) The PCM controls all ignition system functions, and constantly corrects the basic spark timing. The PCM monitors information from various sensor inputs that include the following: ^ The Throttle Position (TP) sensor ^ The Engine Coolant Temperature (ECT) Sensor ^ The Mass Airflow (MAF) Sensor ^ The Intake Air Temperature (IAT) Sensor ^ The Vehicle Speed Sensor (VSS) ^ The transmission gear position or range information sensors ^ The engine Knock Sensors (KS) Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained. You should understand the basic theory of electricity and know the meaning of voltage (volts), current (amps) and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram. Engine Controls Information The driveability and emissions information describes the function and operation of the Powertrain Control Module (PCM). The computers and control systems information contains the following: ^ Component locations ^ Wiring diagrams ^ PCM terminal end view and terminal definitions ^ Powertrain On-Board Diagnostic (OBD) System Check ^ Diagnostic Trouble Code (DTC) tables The Component System includes the following items: ^ Component and circuit description ^ On-vehicle service for each sub-system ^ Functional checks and diagnostic tables The DTCs also contain diagnostic support information containing circuit diagrams, circuit or system information, and helpful diagnostic information. Typical Drive Cycle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3890 Primary System Based Diagnostics There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed, with a brief description of the diagnostic functionality. Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Catalyst Monitor Diagnostic Operation The catalyst monitor diagnostic measures oxygen storage capacity of the catalyst converter. In order to do this, the heated sensors are installed before and after the 3-Way Catalyst (TWC). Voltage variations between the sensors allow the PCM to determine the catalyst emission performance. As a catalyst becomes less effective in promoting chemical reactions, the catalysts capacity to store and release oxygen generally degrades. The catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity. A good catalyst, e.g. 95 degrees hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst Heated Oxygen Sensor ( HO2S). A degraded catalyst, 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S. The post-catalyst HO2S is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The (TWC) and the HO2S must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S outputs graphic. The catalyst monitor diagnostic is sensitive to the following conditions: ^ Exhaust leaks ^ HO2S contamination ^ Alternative fuels Exhaust system leaks may cause the following: ^ Prevent a degraded catalyst from failing the diagnostic ^ Cause a false failure for a normally functioning catalyst ^ Prevent the diagnostic from running Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevent the TWC diagnostic from functioning properly. Catalyst Monitor Heated Oxygen Sensors In order to control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides of Nitrogen (NOx), the system uses a 3-way catalytic converter. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HC and CO into harmless water vapor and carbon dioxide. The catalyst also converts NOx to nitrogen. Catalyst monitor HO2S, post-catalyst HO2S, are always located downstream of the catalytic converter. The PCM has the ability to monitor this process using the post catalyst heated oxygen sensors. The pre-sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the 3-way catalytic converter. The post sensor produces an output signal which indicates the oxygen storage capacity of the catalyst. This in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-HO2S signal is far more active than that produced by the post-HO2S. In addition to catalyst monitoring, the post-HO2S has a limited role in controlling fuel delivery. If the post-HO2S signal indicates a high or low oxygen content for an extended period of time while in a Closed Loop, the PCM adjusts the fuel delivery slightly in order to compensate. Comprehensive Component Monitor Diagnostic Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. Fuel Trim System Operation The fuel trim system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the average of short and long-term fuel trim values. If either value is within the thresholds, a pass is recorded. If either value is outside the thresholds, a rich or lean fuel trim DTC will set. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3891 Misfire Monitor Diagnostic Operation The misfire monitor diagnostic is based on crankshaft rotational velocity, aka reference period, variations. The PCM determines crankshaft rotational velocity using the Crankshaft Position (CKP) Sensor and Camshaft Position (CMP) Sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the PCM can calculate when a misfire occurs. For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1,000 - 3,200 engine revolutions. For catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions. Rough roads may cause false misfire detection. A rough road applies sudden torque variations to the drive wheels and drivetrain. This torque can intermittently decrease the crankshaft rotational velocity. The Antilock Braking (ABS) System detects uneven speed between the vehicles wheels and sends data via the serial data bus to the PCM to disable the misfire monitor until the rough road is no longer detected. On automatic transmission equipped vehicles, the Torque Converter Clutch (TCC) disables whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the effect of the drive wheel inputs on crankshaft rotation. When the TCC has disabled as a result of misfire detection, the TCC is re-enabled after approximately 3,200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to reevaluate the system. Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. A current and a history misfire counter is maintained for each cylinder. The misfire current counters, Misfire Cur #1 - 8, indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters displays real time data without a misfire DTC stored. The misfire history counters, Misfire Hist #1 - 8. indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events. The Misfire counters graphic illustrates how these misfire counters are maintained. When crankshaft rotation is erratic, the PCM detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3892 sometimes incorrectly identify which cylinder is misfiring. The Misfire Counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 - Misfire Detected. The illustration depicts an accumulation in the history buffers. If two cylinders in sequential firing order are both misfiring, the first misfiring cylinder will accumulate misfires in its buffer, but the second misfiring cylinder will not. This is because the PCM compares a misfiring cylinder with the cylinder 90 degrees prior to it in the firing order. Therefore the PCM would be comparing crankshaft speed of the second misfiring cylinder to an already suspect cylinder. The PCM however, will be able to detect both misfiring cylinders after the engine exceeds 2,000 RPM. This is because the PCM then starts to compare misfires to the opposing cylinder rather than the previous cylinder in the firing order. Use Techline equipment to monitor the misfire counter data on applicable vehicles, knowing which specific cylinders misfire can lead to the root cause. Using the information in the misfire counters identifies which cylinders are misfiring. If the counters indicate cylinders number 1 and 4 misfired, look for a circuit or component common to both cylinders. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: ^ Contaminated fuel ^ Running out of fuel ^ Fuel fouled spark plugs ^ Basic engine fault Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor PCM Function The PCM supplies a buffered voltage to various sensors and switches. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the PCM circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the PCM circuits unless instructed. Only test these circuits with a DMM while the PCM connectors remain connected. Three-Way Catalyst Oxygen Storage Capacity Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3893 Three-Way Catalyst Storage Capacity The PCM must monitor the 3-Way Catalyst System (TWC) for efficiency. In order to accomplish this, the PCM monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor shows significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores oxygen during the normal reduction and oxidation process. The TWC releases oxygen during its normal reduction and oxidation process. The PCM calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor voltage levels. Misfire Monitor Diagnostic Tests Whenever the sensor activity of the post-catalyst (2) oxygen sensor nears the sensor activity of the pre-catalyst (1) oxygen sensor, the catalysts efficiency is degraded. Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of precious metal content as the original pan, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC. Torque Management Torque management is a function of the PCM that reduces engine power under certain conditions. Torque management is performed for the following reasons: 1. To prevent over-stressing the powertrain and driveline components 2. To prevent damage to the vehicle during certain abusive maneuvers 3. To reduce engine speed when the IAC is out of the normal operating range The PCM monitors the following sensors and engine parameters in order to calculate engine output torque: ^ The air/fuel ratio ^ The Mass Air Flow (MAF) sensor ^ The Manifold Absolute Pressure (MAP) sensor ^ The Intake Air Temperature (IAT) sensor ^ The spark advance ^ The engine speed ^ The Engine Coolant Temperature (ECT) sensor ^ The A/C clutch status The PCM monitors the torque converter status, the transmission gear ratio, and the engine speed in order to determine if torque reduction is required. The PCM retards the spark as appropriate to reduce engine torque output if torque reduction is required. The PCM also shuts OFF the fuel to certain injectors in order to reduce the engine power in the case of an abusive maneuver. The following are instances when engine power reduction is likely to be experienced: ^ During transmission upshifts and downshifts ^ During heavy acceleration from a standing start ^ When the clutch pedal is released too quick under a heavy load (6.0L only) ^ When one set of drive axles loses traction while the other set of drive axles are not moving (4WD only and in 4WD low) ^ If the IAC is out of the normal operating range, except 6.0L ^ When the driver is performing harsh or abusive maneuvers such as shifting into gear at high throttle angles or shifting the transmission from reverse to drive to create a rocking motion The driver is unlikely to notice the torque management actions in the first 2 instances. The engine power output is moderate at full throttle in the other cases. The PCM calculates the amount of spark retard necessary to reduce the engine power by the desired amount. The PCM disables the fuel injectors for Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3894 cylinders 1, 4, 6, and 7 in the case of an abusive maneuver. Powertrain Control Module Powertrain Control Module The Powertrain Control Module (PCM) is located in the engine compartment. The PCM is the control center of the vehicle. It controls the following: ^ The fuel metering system ^ The transmission shifting ^ The ignition timing ^ The on-board diagnostics for powertrain functions The PCM constantly monitors the information from various sensors and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic functions for those systems. The PCM can recognize operational problems and alert the driver through the Malfunction Indicator Lamp (MIL) when a malfunction has occurred. When a malfunction is detected, the PCM stores a Diagnostic Trouble Code (DTC) which helps to identify problem areas. This is done to aid the technician in making repairs The PCM supplies either 5.0 or 12.0 volts to power various sensors and switches. This is done through resistances in the PCM. The resistance is so high in value that a test lamp does not illuminate when connected to the circuit. In some cases, even an ordinary shop voltmeter does not give an accurate reading because the voltmeters resistance is too low. Therefore, a DMM with a minimum of 10 megaohms input impedance is required to ensure accurate voltage readings. The PCM controls output circuits such as the fuel injectors, the Idle Air Control (IAC), the cooling fan relays, etc. by controlling the ground or the power feed circuit through transistors or a device called an output driver module. The Powertrain Control Module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Input Components The PCM monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, such as a Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. The input components may include, but are not limited to, the following sensors: ^ The Vehicle Speed Sensor (VSS) ^ Mass Air Flow (MAF) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Crankshaft Position (CKP) Sensor ^ Knock Sensor (KS) ^ Throttle Position (TP) Sensor ^ Engine Coolant Temperature (ECT) Sensor ^ Camshaft Position (CMP) Sensor ^ Manifold Absolute Pressure (MAP) Sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable Closed Loop fuel control. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > General Information > Page 3895 Output Components Diagnose the output components for the proper response to PCM commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: ^ The Idle Air Control (IAC) motor ^ The EVAP system ^ The electronic transmission controls ^ The A/C relay, if so equipped ^ The Vehicle Speed Sensor (VSS) output ^ The Malfunction Indicator Lamp (MIL) control ^ The cruise control enable, if so equipped Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information Engine Control Module: Service and Repair Additional Information The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3898 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3899 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (Off-board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: ^ DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. ^ The Off-Board Programming is used in situations where a control module must be programmed without having the vehicle present. The Off-Board Programming Adapter must be used to perform the Off-Board Programming procedure. The adapter allows the control module to power up and allows the Tech 2 to communicate with the control module. ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Ensure that all connections are secure at the following locations: ^ The Off-Board Programming Adapter ^ The Tech 2 ^ The control module ^ The Techline terminal OFF-BOARD PROGRAMMING 1. Obtain the VIN of the vehicle for which the control module is being programmed. 2. With the Techline terminal, select Service Programming. 3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the electronic control unit (ECU) location. 4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described on the Techline terminal. Ensure you use the correct harness connector from the Off-Board Programming Adapter kit. 5. With the Tech 2, select Service Programming Request Information function. The Tech 2 communicates with the control module and receives the access code. 6. With the Tech 2, exit the Service Programming Request Information. 7. Disconnect the Tech 2 from the Off-Board Programming Adapter. 8. Connect the Tech 2 to the Techline terminal. 9. Turn ON the Tech 2. 10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control module. 11. The Techline terminal will display the message, attaching to database. 12. Identify what type of programming that you are performing. 13. Select the appropriate calibration file. 14. Ensure all connections are secure. 15. The Techline terminal displays a summary screen that summarizes your selections. After confirming you choices, the Techline terminal automatically loads the calibration files to the Tech 2. 16. After the download is complete, turn OFF the Tech 2. 17. Disconnect the Tech 2 from the Techline terminal. 18. Connect the Tech 2 to the Off-Board Programming Adapter. 19. With the Tech 2, select Service Programming. IMPORTANT: DO NOT turn OFF the Off-Board Programming Adapter if the programming procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board Programming Adapter connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 20. With the Tech 2, select Program. 21. After the download is complete, exit Service Programming. 22. Turn OFF the Off-Board Programming Adapter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3900 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Programming (On-Board) BEFORE PROGRAMMING A CONTROL MODULE IMPORTANT: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: ^ Vehicle system voltage There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. ^ Twilight sentinel ^ Interior lights ^ Daytime running lights (DRL) - Applying the parking brake, on most vehicles, disables the DRL system. ^ HVAC systems ^ Engine cooling fans etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. ^ All tool connections are secure. RS-232 - The connection at the data link connector (DLC) is secure. - Voltage supply circuits ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. REMOTE PROGRAMMING 1. Turn OFF the ignition. 2. Install the Tech 2 to the DLC. 3. Turn ON the ignition, with the engine OFF. 4. Turn OFF all vehicle accessories. 5. With the Tech 2, select Service Programming. 6. Identify vehicle information as requested by the Tech 2. 7. Select the type of module you are programming. 8. Select the type of programming to be performed. 9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN, write down the actual VIN and correct the VIN at the Techline terminal. 10. When complete, Exit Service Programming. 11. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle. 12. Turn OFF the ignition. 13. Connect the Tech 2 to the Techline terminal. 14. Select Service Programming. 15. Select Tech 2 as the tool you are using. 16. Select the type of programming to be performed. 17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary. 18. Select the type of module you are programming. 19. Identify what type of programming that you are performing. ^ Normal - This type of programming is for updating an existing calibration or programming a new controller. ^ Vehicle configuration index (VCI) - This selection is used if the vehicle VIN is unavailable or not recognized by the Techline terminal. Observe, you will need to contact the Techline Customer Support center to use this option. ^ Reconfigure - This is to reconfigure a vehicle, such as tire size and axle ratio changes. 20. Select the appropriate calibration file. 21. Ensure all connections are secure. 22. Select Reprog to initiate the download of the new calibration to the Tech 2. 23. After the download is complete, turn OFF the Tech 2. 24. Disconnect the Tech 2 from the Techline terminal. 25. Install the Tech 2 to the data link connector (DLC). 26. Turn ON the Tech 2. 27. Turn ON the ignition, with the engine OFF. 28. Select Service Programming. IMPORTANT: DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all the PCM and DLC Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3901 connections are secure and the Techline operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module. 29. Select Program. 30. After the download is complete, EXIT Service Programming. 31. Turn OFF the ignition for 30 seconds. 32. Turn OFF the Tech 2. 33. If a control module is replaced the following service procedures must be performed: ^ The Crankshaft Variation Learn Procedure ^ The Engine Oil Life Reset Procedure ^ The Idle Learn Procedure ^ The Inspection/Maintenance Complete System Set Procedure ^ The Vehicle Theft Deterrent Password Learn Procedure ^ The TP Sensor Learn Procedure PROGRAMMING VERIFICATION 1. With a scan tool, clear the DTCs. 2. Attempt to start the engine. 3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the following procedures before programming the PCM: ^ Ensure the control module and DLC connections are OK. ^ Ensure the Techline operating software is up to date. ^ Ensure the calibration part number is correct for the vehicle. 4. Attempt to program the control module. If the control module still cannot be programmed properly, replace the control module. You must program the replacement control module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3902 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Replacement Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first to see if the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM. IMPORTANT: ^ To prevent internal PCM damage, the ignition must be OFF when disconnecting or reconnecting power to the PCM. For example, when working with a battery cable, PCM pigtail, PCM fuse, or jumper cables. ^ Remove any debris from the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. ^ The replacement PCM must be programmed. Removal Procedure NOTE: ^ Refer to PCM and ESD Notice in Service Precautions. ^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. 1. Disconnect the PCM harness connectors (4). 2. Release the spring latch (3) from the PCM (1). 3. Lift the PCM from the PCM mounting tray (2). 4. Remove the PCM (1) from the engine compartment. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3903 1. Install the PCM (1) to the PCM mounting tray (2). 2. Secure the spring latch (3) to the PCM (1). NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the PCM connectors (4) to the PCM (1). Tighten Tighten the PCM connector end fasteners to 8 N.m (71 lb in). 4. If a new PCM is being installed, program the PCM. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3904 Engine Control Module: Service and Repair Service Programming System (SPS) The Service Programming System (SPS) allows a technician to program a control module through the Data Link Connector (DLC). The information transfer circuit that is used at the DLC is the same serial data circuit used by the scan tool for retrieving Diagnostic Trouble Codes (DTCs), displaying data, clearing DTCs, etc. This procedure offers the ability to install software/calibrations matched to a particular vehicle. Most control modules have 2 types of memory. The software/calibrations reside in the flash memory. The two types of memory are listed below: ^ Electrically Erasable Programmable Read Only Memory (EEPROM) This type of memory allows selected portions of memory to be programmed while other portions remain unchanged. Certain learned values reside in the EEPROM, such as: ^ The Vehicle Identification Number (VIN) ^ The crankshaft variation learned position ^ The software/calibrations identification numbers ^ The control module security information ^ Flash Read Only Memory - Rash Memory Flash memory has increased memory storage capacity. During programming, all information within this type of memory is erased, and then replaced with entirely new information. Service Programming Methods The 4 methods of programming a control module and the proper tools for each method are as follows: ^ Remote Programming: The Tech 2 or other scan tool, Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle ^ Pass Thru Programming: The Tech 2 or other scan tool Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software - The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is installed in the vehicle. ^ Off-Board Remote Programming, vehicle NOT available: The Tech 2 or other scan tool, Off-board Programming Adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle ^ Off-Board Pass Thru Programming The Tech 2 or other scan tool, off-board programming adapter (OBPA), Techline Terminal or a personal computer equipped with General Motors Corporation authorized programming software The Tech 2 or other scan tool is used as an interface between the vehicle and the Techline Terminal or a personal computer. - The control module is NOT installed in a vehicle Before Programming a Control Module IMPORTANT: DO NOT program an existing control module with the identical software/calibration package. This procedure is not a short cut to correct a driveability condition. This is an ineffective repair. A control module should only be programmed when the following occurs: ^ When a service procedure instructs you to replace the control module. The service part control module does not contain operating software or calibrations. ^ General Motors Corporation releases an updated software/calibration package. Ensure that the following conditions are met before programming a control module: ^ Vehicle system voltage: There are no charging system concerns. All charging system concerns must be repaired before programming a control module. - The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully charged before programming the control module. - A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or disable systems such as: ^ Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the DRL system. ^ Heating, Ventilation, And Air Conditioning (HVAC) systems ^ Engine cooling fans, etc. ^ The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so. ^ All tool connections are secure: The RS-232 cable - The connection at the DLC - The voltage supply circuits - The OBPA ^ DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Additional Information > Page 3905 control module damage may occur. ^ If you are performing the pass-through programming procedure using a notebook computer without the power cord, ensure that the internal battery is fully charged. After Programming A Control Module The powertrain may operate slightly different after a control module software/calibration update. Operating the powertrain through various driving conditions allows the control module to re-learn certain values. The control module must re-learn the following after a software/calibration update: ^ Fuel trim correction ^ Idle Air Control (IAC) learned position ^ Automatic transmission shift adapts Other learned values only re-learn by performing a service procedure. If a control module is replaced the following service procedures may need to be performed: ^ The crankshaft variation learn procedure ^ The engine oil life reset procedure ^ The idle learn procedure ^ The inspection/maintenance complete system set procedure ^ The vehicle theft deterrent password learn procedure ^ The Throttle Position (TP) sensor learn procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3912 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3913 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3914 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3915 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3944 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3945 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3946 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Diagrams > Page 3947 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3985 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3986 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3987 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3988 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3989 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3990 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3991 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3992 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3993 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor Torque ................................................................................................................................................. ................................................................ 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3997 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3998 Engine Coolant Temperature (ECT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3999 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 4000 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Drain the cooling system. 2. Remove the engine cover. 3. Remove the coolant temperature sensor electrical connector from the electrical harness at the intake manifold. 4. Remove the coolant temperature sensor electrical connector from the intake manifold bracket. 5. Remove the coolant temperature sensor from the cylinder head. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the coolant temperature sensor to the cylinder head. Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Snap the coolant temperature sensor electrical connector to the intake manifold bracket. 3. Connect the coolant temperature sensor electrical connector to the wiring harness at the intake manifold. 4. Install the engine cover. 5. Fill the cooling system with coolant. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 4009 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 4015 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4016 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4051 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4052 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4055 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4056 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4057 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4058 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4059 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4063 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure (FTP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4067 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) Sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1 - 4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4068 Fuel Tank Pressure Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4069 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor (1) from the modular fuel sender (2). INSTALLATION PROCEDURE 1. Install the fuel tank pressure sensor (1) to the modular fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4073 Intake Air Temperature (IAT) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4074 Intake Air Temperature Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4075 Intake Air Temperature Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor harness connector. 3. Remove the IAT sensor from the air cleaner outlet duct by pulling the sensor upward. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4076 1. Install the IAT sensor in the air cleaner outlet duct. 2. Connect the IAT sensor harness connector. 3. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4114 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4115 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4116 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4120 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4121 Manifold Absolute Pressure (MAP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4122 Manifold Pressure/Vacuum Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4123 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE Other than checking for a worn grommet and loose electrical connectors, the only service possible is a unit replacement if the diagnosis shows a malfunctioning manifold absolute pressure (MAP) sensor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the MAP sensor harness connector. NOTE: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 4. Remove the MAP sensor by pulling straight up with a slight rocking motion. 5. Remove the MAP sensor grommet. 6. Discard the MAP sensor grommet. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4124 1. Install the new MAP sensor grommet on the MAP sensor. 2. Install the MAP sensor. 3. Connect the MAP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Engine Oil Pressure Gage Sensor Torque ................................................................................................................................................. ................................................................ 22 ft. lbs. Engine Oil Pressure Gage Sensor Fitting (Plus Required Angle) Torque.................................................................................................................................................. ............................................................... 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 4128 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required J41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the engine cover. 2. Disconnect the engine oil pressure sensor gage electrical connector. 3. Hold the engine oil pressure gage sensor fitting with a wrench. 4. Remove the engine oil pressure gage sensor using J41712. Important: Note the alignment of the engine oil pressure gage sensor fitting prior to removal. 5. Remove the engine oil pressure gage sensor fitting, if necessary. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure gage sensor fitting, if removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications > Page 4129 1.1. Tighten the engine oil pressure gage sensor fitting to 15 Nm (11 ft. lbs.). Important: Do not loosen the sensor fitting. Do not tighten the sensor fitting more than one turn to align. 1.2. Tighten the sensor fitting until properly aligned. 2. Install the engine oil pressure gage sensor. 3. Hold the engine oil pressure gage sensor fitting with a wrench to prevent from turning. Using J41712 tighten the engine oil pressure gage sensor to 30 Nm (22 ft. lbs.). 4. Install the engine oil pressure gage sensor electrical connector. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Oxygen Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Oxygen Sensor: Connector Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors Oxygen Sensor: Description and Operation Heated Oxygen Sensors The main function of the pre-catalyst Heated Oxygen Sensor (HO2S) is to provide the (PCM) with exhaust stream information in order to maintain proper fueling to hold emissions within acceptable levels. These oxygen sensors are always located between the exhaust manifold and the catalytic converter. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases. The PCM uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in a Closed Loop, the PCM can adjust fuel delivery in order to maintain an air to fuel ratio which allows the best combination of emission control and driveability. If the oxygen sensor pigtail wiring, connector, or terminal are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided to it. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference. Any attempt to repair the wires, connectors, or terminals could degrade oxygen sensor performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensors > Page 4170 Oxygen Sensor: Description and Operation Oxygen Sensor Diagnosis Diagnose the fuel control heated oxygen sensors for the following conditions: ^ Heater performance, time to activity on cold start ^ Slow response ^ Response time, time to switch R/L or L/R ^ Inactive signal, output steady at bias voltage - approximately 450 mV ^ Signal fixed high ^ Signal fixed low Diagnose the catalyst monitor heated oxygen sensors for the following functions: ^ Heater performance, time to activity on cold start ^ Signal fixed low during steady state conditions ^ Inactive sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 4171 Oxygen Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (1) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (2) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4174 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (2) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (1). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4175 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (3) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (4) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4176 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5613695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (4) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (3). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4177 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 1 TOOLS REQUIRED J 39194-B Oxygen Sensor Wrench REMOVAL PROCEDURE CAUTION: Refer to Vehicle Lifting Caution in Service Precautions. 1. Raise the vehicle. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Service Precautions. 2. Disconnect the connector (2) for the HO2S. NOTE: Refer to Excessive Force and Oxygen Sensor Notice in Service Precautions. 3. Remove the HO2S (1) using a J 39194-B. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 1 > Page 4178 1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 5813695, if necessary. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the HO2S (1) using a J 39194-B. Tighten Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S harness connector (2). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4215 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4216 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4217 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4218 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4222 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4223 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4224 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4225 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4226 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4252 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4253 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4254 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4255 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4256 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4257 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4258 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Vehicle Speed Sensor (VSS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4283 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4284 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4285 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4286 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4287 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4288 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4289 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4290 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4291 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4292 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4293 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4294 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4295 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4296 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4297 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4298 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4299 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4301 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4302 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 4303 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4307 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4308 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4309 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4310 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4311 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Vehicle Speed Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4325 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4328 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4329 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4330 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4331 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4348 Vehicle Speed Sensor (VSS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications Catalytic Converter: Specifications Catalytic Converter-to-Muffler Nuts Torque ................................................................................................................................................. ................................................. 40 Nm (30 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 4353 Catalytic Converter: Service and Repair Catalytic Converter Replacement (RWD) Removal Procedure Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the catalytic converter assembly. 3. Remove the 3 oxygen sensor electrical connections and clips. 4. Remove the nuts from the muffler flange bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 4354 5. Remove the nuts from the exhaust manifold studs (right side). 6. Disconnect the collars from the exhaust manifold studs (right side). 7. Remove the nuts from the exhaust manifold studs (left side). 8. Disconnect the collars from the exhaust manifold studs (left side). 9. Remove the catalytic converter assembly from the muffler assembly. 10. Remove the catalytic converter assembly from the exhaust manifolds. 11. Lower the front of the catalytic converter assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 4355 12. Remove the catalytic converter assembly from the hanger. Notice: Do not damage the oxygen sensors when removing the catalytic converter. 13. Remove the catalytic converter assembly from the vehicle by rotating the assembly over the rear of the transmission crossmember. 14. Remove the 3 oxygen sensors. Installation Procedure When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear. In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps. Important: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed. - When exhaust system service requires removing and replacing an oxygen sensor, refer to the applicable service procedure. - Always use new nuts when installing the exhaust pipe to the exhaust manifold. - Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush. 1. Install the 3 oxygen sensors to the catalytic converter assembly. 2. Install the catalytic converter assembly to the hanger. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 4356 3. Install the collars on the catalytic converter assembly to the exhaust manifold studs (left side). 4. Loosely install the nuts onto the exhaust manifold studs (left side). 5. Install the collars on the catalytic converter assembly to the exhaust manifold studs (right side). 6. Loosely install the nuts onto the exhaust manifold studs (right side). 7. Connect the catalytic converter assembly and the gasket to the muffler assembly. 8. Loosely install the nuts. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 4357 9. Tighten the exhaust manifold nuts in proper sequence (1-6). - Tighten the catalytic converter assembly-to-exhaust manifold nuts to 53 Nm (39 ft. lbs.). - Tighten the catalytic converter assembly-to-muffler assembly nuts to 40 Nm (30 ft. lbs.). 10. Install the three oxygen sensor electrical connections and clips. 11. Remove the support from the catalytic converter assembly. 12. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Remove the engine wiring harness bracket from the stud. 3. Disconnect the evaporative emissions (EVAP) canister purge pipe. 4. Disconnect the EVAP canister purge valve harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4362 5. Remove the EVAP canister purge valve mounting nuts. 6. Remove the EVAP canister purge valve from the intake manifold. INSTALLATION PROCEDURE 1. Install the EVAP canister purge valve to the intake manifold. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4363 2. Install the EVAP canister purge valve mounting nuts. Tighten Tighten the nuts to 12 N.m (106 lb in). 3. Connect the EVAP canister purge valve harness connector. 4. Connect the EVAP canister purge pipe. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4364 5. Install the engine wiring harness bracket to the stud. Tighten Tighten the bracket nut to 8 N.m (71 lb in). 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations Locations View Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 4369 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 4370 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 4371 Evaporator Emission (EVAP) Canister Purge Solenoid Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 4372 Canister Purge Solenoid: Description and Operation EVAP VENT VALVE The EVAP vent valve controls fresh airflow into the EVAP canister. It is a normally open valve. The control module will command the valve closed during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 4377 Evaporator Emission (EVAP) Canister Vent Solenoid Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 4378 Canister Vent Valve: Service and Repair REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the evaporative emission (EVAP) canister vent valve bracket bolt (5) from the vent valve bracket (1). 3. Disconnect the vent valve harness connector (4) from the vent valve (6). 4. Disconnect the vent pipe (3) from the vent valve (6). 5. Remove the vent valve. 6. Remove the vent valve from the bracket. INSTALLATION PROCEDURE 1. Install the vent valve on the bracket. 2. Install the EVAP canister vent pipe (3) on the EVAP canister vent valve (6). 3. Connect the EVAP canister vent valve harness connector (4) to the EVAP canister vent valve. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the EVAP canister vent valve bracket (1) and the vent valve bracket bolt (5). Tighten Tighten the retaining bolt to 10 N.m (89 lb in). 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine REMOVAL PROCEDURE IMPORTANT: When replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. 1. Remove the engine cover. 2. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system. 3. Disconnect the engine compartment EVAP pipe at the EVAP canister purge valve. 4. Disconnect the engine compartment EVAP pipe (1) at the chassis EVAP pipe (2). 5. Remove the EVAP pipe from the engine. 6. Cap the EVAP canister purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4383 1. Remove the caps from the EVAP canister purge valve and the chassis EVAP pipe. 2. Install the EVAP pipe on the engine. 3. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2). 4. Connect the engine compartment EVAP pipe at the EVAP canister purge valve. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4384 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the EVAP vapor pipe (5) from the EVAP canister (1). 3. Disconnect the EVAP vapor pipe from the fill limiter vent valve (2). 4. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Connect the EVAP vapor pipe (5) to the till limiter vent valve (2). 2. Connect the EVAP vapor pipe to the EVAP canister (1). 3. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4385 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Chassis/Canister REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the rear chassis EVAP purge pipe (3) from the EVAP canister (1). 3. Remove the rear chassis EVAP purge pipe. INSTALLATION PROCEDURE 1. Connect the rear chassis EVAP purge pipe (3) to the EVAP canister (1). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4386 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis REMOVAL PROCEDURE 1. Remove the engine cover. 2. Clean all the pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination. 3. Disconnect the chassis EVAP pipe from the engine compartment EVAP purge pipe (9). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the fuel/EVAP pipes bundle retainer mounting stud (7) from the cylinder head. 6. Remove the fuel/EVAP pipes bundle retainer mounting stud (6) from the transmission. 7. Remove the fuel/EVAP pipes bundle retainer mounting fastener (5) from the crossrail. 8. Disconnect the front chassis EVAP purge pipe from the rear chassis EVAP purge pipe (4). 9. Note the position of the EVAP pipe for aid in installation. 10. Remove the EVAP pipe from the retaining clips. 11. Remove the EVAP pipe. INSTALLATION PROCEDURE IMPORTANT: ^ When replacing the fuel/EVAP pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection. ^ Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4387 1. Connect the front chassis EVAP pipe to the rear chassis EVAP purge pipe (4). 2. Install the EVAP pipe into the transmission bracket retainer. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the mounting stud (6). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 4. Install the EVAP pipe into the cylinder head retainer. 5. Install the mounting stud (7). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 6. Install the EVAP pipe into the crossrail retainer. 7. Install the mounting bolt (5) to the crossrail. Tighten Tighten the mounting bolt to 11 N.m (97 lb in). 8. Lower the vehicle. 9. Connect the chassis EVAP pipe to the engine compartment EVAP pipe (9). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine > Page 4388 10. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation The EVAP service port is located in the EVAP purge pipe between the EVAP purge valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 4401 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 4402 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Lift upward on the accelerator pedal (3) to relieve tension on the cable (2). 2. Remove the retainer (1) from the pedal lever (4) hole. 3. Remove cable (2) from the slot in the pedal lever (4). 4. Remove the accelerator pedal mounting fasteners. 5. Remove the accelerator pedal assembly. INSTALLATION PROCEDURE IMPORTANT: The accelerator cable is not to be kinked or damaged in any way during installation. Ensure that the mounting surface between the accelerator pedal assembly and the dash panel is free of insulation. The carpet and padding in the pedal area must be positioned to lay flat and be free of wrinkles and bunches. Wire, hoses, cables, and other flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any point in their travel. 1. Place the accelerator pedal assembly on the mounting surface. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the three mounting bolts. Tighten Tighten the pedal assembly to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 4409 3. Lift upward on the accelerator pedal (3). 4. Insert the cable (2) through the pedal lever slot. 5. Press the retainer (1) into the lever hole until fully seated. IMPORTANT: The pedal must operate freely without binding through the full range of pedal movement. 6. Check the pedal (3) for free movement by pressing down on the pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Restriction Indicator > Component Information > Description and Operation Air Cleaner Restriction Indicator: Description and Operation The air cleaner restriction indicator is located on the intake duct between the air cleaner assembly and the Mass Air Flow/Intake Air Temperature ( MAF/IAT) sensor. If the area inside of the clear section is green, no air filter service is required. If the area inside the clear section is orange and Change Air Filter appears, replace the air filter. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4422 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 4428 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4429 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner cover by releasing the retainer clips. 2. Remove the air cleaner element. 3. Clear out any debris in the air cleaner tub. INSTALLATION PROCEDURE 1. Insert the air cleaner element into the air cleaner tub. 2. Install the air cleaner cover. 3. Fasten the air cleaner cover retainer clips. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4439 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4441 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4442 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4458 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4467 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4468 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4469 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4470 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4475 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4476 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4477 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4478 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4479 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4480 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 4481 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 4482 Fuel: Description and Operation FUEL SYSTEM SPECIFICATIONS Use regular unleaded gasoline rated at 87 octane or higher. The manufacturer recommends that the gasoline meet the specifications which have been developed by the American Automobile Manufacturers Association (AAMA) and endorsed by the Canadian Motor Vehicle Manufacturers Association for better vehicle performance and engine protection. Gasoline meeting the AAMA specification may provide improved driveability and emission control system performance compared to other gasoline. For more information, write to: American Automobile Manufacturer's Association, 7430 Second Ave., Suite 300, Detroit, MI, 48202. Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. Severe knocking may damage your engine. If you are using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs service. Do not worry if you hear a little pinging noise when you are accelerating or driving up a hill. This is normal and you do not have to buy a higher octane fuel to get rid of pinging. Only the heavy, constant knock means that you have a problem. NOTE: Your vehicle was not designed for fuel that contains methanol. Do not use methanol fuel which can corrode metal parts in your fuel system and also damage plastic and rubber parts. This kind of damage would not be covered under your warranty. If your vehicle is certified to meet California emission standards, indicated on the underhood emission control label, is designed to operate on fuels that meet California specifications. If such fuels are not available in states adopting California emission standards, your vehicle operates satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The Malfunction Indicator Lamp (MIL) on your instrument panel may turn ON, and your vehicle may fail a smog-check test. If this occurs, return to your authorized dealer for diagnosis in order to determine the cause of failure. If the type of fuel you used caused the condition, repairs may not be covered by your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called Methylcyclopentadienyl Manganese Tricarbonyl (MMT). Ask your service station operator whether or not the fuel contains MMT. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool Fuel: Testing and Inspection With Special Tool TEST DESCRIPTION Fuel quality can effect vehicle performance. Gasoline and gasoline blends that are contaminated or contain excessive amounts of alcohol can effect vehicle driveability, fuel economy, fuel system components and emissions. Excessive alcohol in the fuel may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions in vehicles such as hesitation, lack of power, stalling, or no start. If excessive alcohol in the fuel is suspected, then use the following procedure to test the fuel quality. TEST PROCEDURE 1. Turn ON the J 44175 Fuel Composition Tester. 2. Verify that the fuel composition tester is operational by measuring the AC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal. IMPORTANT: Bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample from the vehicle being tested. 4. Close the bleed valve on the fuel pressure gage. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker (2). 6. Command the fuel pump ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, clean the fuel system and replace the fuel in the vehicle. Refer to Fuel System Cleaning. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 4485 IMPORTANT: DO NOT allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the J 44175 could result in misdiagnosis. 9. Pour the fuel sample from the beaker (1) into the J 44175, until the level of the fuel is at the top of each fuel test port (2). 10. Observe the diagnostic LEDs on the fuel composition tester. If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Alcohol/Contaminants-in-Fuel Diagnosis (With Special Tool) 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 10 percent ethanol, replace the fuel in the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 4486 Fuel: Testing and Inspection Without Special Tool Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel meter body assembly, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of more than 10 percent in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Fuel contaminated with alcohol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Some types of alcohol are more detrimental to fuel system components than others. Alcohol In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. 3. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 4. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Page 4487 Fuel: Service and Repair FUEL SYSTEM CLEANING REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel sender assembly. 3. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump. 4. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state and federal laws and regulations. 5. Flush the fuel lank with hot water. 6. Pour the water out of the fuel sender assembly opening. 7. Rock the fuel tank to be sure that the removal of water from tank is complete. 8. Inspect the in-line fuel filter for contamination. 9. Replace the fuel filter if the filter is plugged. IMPORTANT: Only use oil free compressed air to blow out the fuel pipes. 10. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow. 11. Install the fuel sender assembly with a new seal into the fuel tank. 12. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. Fuel Filler Cap The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions. 1. Remove the engine cover. CAUTION: Refer to Fuel Gage Leak Caution in Service Precautions. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: ^ The fuel pipe connections ^ The hose connections ^ The areas surrounding the connections 2. Install the J 34730-1A to the fuel pressure service connection. 3. Turn ON the ignition. CAUTION: Refer to Fuel Storage Caution in Service Precautions. 4. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 6. Command the fuel pump ON with a scan tool. 7. Close the bleed valve on the fuel pressure gage. 8. Inspect for fuel leaks. REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 4496 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed OFF fuel system pressure. 2. Place a shop towel under the J 34730-1A to catch any remaining fuel spillage. 3. Remove the J 34730-1A from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 4497 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Turn OFF the ignition. 2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. 3. Remove the engine cover. 4. Connect the J 34730-1A or the equivalent to the fuel pressure connection. 5. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage. 6. Install the bleed hose of the gage into an approved container. 7. Open the valve on the gage in order to bleed the system pressure. The fuel connections are now safe for servicing. 8. Drain any fuel remaining in the gage into an approved container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Recalls: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed Fuel Injector: Recalls Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Recalls: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4506 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Recalls: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4507 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Recalls: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4508 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Recalls: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4509 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up Technical Service Bulletin # 00-06-04-003B Date: 030201 Fuel System - MIL ON/Rough Idle on Start-Up File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-003B Date: February, 2003 TECHNICAL Subject: Rough Idle After Start, And/Or A Service Engine Soon (SES) Light (Unstick And Clean Central Sequential Fuel Injection (CSFI) Poppet Valves or Convert to MFI) Models: 1995-2002 Chevrolet and GMC S/T Models 1996-2002 Chevrolet and GMC C/K, M/L, G, P Models 1996-2001 Oldsmobile Bravada 1999-2000 Cadillac Escalade with 4.3L, 5.0L or 5.7L Engine (VINS W, X, M, R - RPOs L35, LF6, L30, L31) Except 2002 VIN X - RPO LU3 Models This bulletin is being revised to update the Warranty Information. Please discard previous copies of Corporate Bulletin Number 00-06-04-003B with warranty chart (Section 06 - Engine). This copy is for Dealers in the state of CALIFORNIA ONLY. Condition Some customers may comment on rough idle after start-up, especially if the vehicle has sat overnight. These symptoms may be intermittent. The Service Engine Soon (SES) light may also be illuminated. Current misfire or history misfire codes may be detected with the Tech 2 scan tool. Cause A deposit build-up on the CSFI poppet valve ball and/or seat may cause the poppet ball to stick open or closed. In either case, the specific cylinder will be mis-fueled, resulting in a cylinder mis-fire condition. Correction A new injector unsticking and cleaning process has proven to be effective in restoring poppet valves to an "as new" condition. CSFI injector replacement should NOT be considered as a correction for this customer concern. Check the vehicle history to determine if the vehicle is returning for a second fuel system repair for this condition. If the fuel system has been repaired for this condition previously, then inform the customer that an alternate fix is available. A new MFI fuel system has been developed that will back service the CSFI fuel system. The MFI fuel system eliminates the CSFI poppet valve ball and seat. The CSFI fuel system will need to be replaced as a unit. Refer to Central SFI to MFI Conversion instructions in this bulletin. Notice: Individual CSFI injectors can not be replaced with MFI injectors. The entire CSFI fuel meter body will need to be replaced. The bracket used to retain the injectors in the fuel meter body is different between the CSFI and MFI unit. The unit may not seal if you mix injectors. Severe engine damage could result. Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should return for the same repair, then the CSFI unit can be replaced with an MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. Important: "GM of Canada" dealers require District Service Manager approval prior to replacing the CSFI unit with a MFI unit under warranty. The first step of this process is to use the J 41413 Evap Pressure/Purge Station, in conjunction with the J 44466-10 pressure regulator/hose assembly, to provide the required high pressure (150 psi) source to perform the unsticking procedure. The J 39021 fuel injector tester and accessories provide the means to "energize" the injector. Some later model-year vehicles may utilize the Tech 2(R) to "energize" the injectors. The second step of this process is to run the engine on a solution of 10% Top Engine Cleaner and 90% gasoline. This will effectively clean any deposits from the ball and seats of the poppets. It is very important that the engine fuel system is separated from the vehicle fuel system. Top Engine Cleaner may have detrimental effects on the fuel pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4515 Parts Information Cleaning Procedure Parts CSFI to MFI Conversion Parts Parts are currently available from GMSPO. Warranty Information Important: Some California vehicles may be covered by Special Policy 99066E if built with California Emissions RPO YF5. If the vehicle is covered by the special policy, then that warranty information should be used. For vehicles repaired under warranty, use information contained in Special Policy 99066E. Information This procedure should be performed before any attempt to convert the fuel system to MFI. S/T and C/K Truck 1. Loosen the fuel filler cap to relieve vapor pressure in the fuel tank. 2. Remove the Positive Crankcase Ventilation (PCV) clean air tube from the air inlet tube and set aside. 3. Remove the bonnet and inlet tube from the throttle body. 4. Remove the brake booster vacuum hose and connector from the intake manifold. 5. Remove the electrical connector from the CSFI fuel metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4516 6. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 7. Remove the fuel line bolt (4) at the rear of the intake manifold. 8. Relieve the fuel system pressure at the service fitting on the fuel line. Use a shop towel to contain any fuel that may exit the service fitting. 9. Remove the nuts (1) and clamp (2) from the fuel pipe. 10. Remove the fuel pipes from the metering body. Be careful not to disturb the O-rings, washer, and spacer in the metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4517 11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install the J 44466-11 (4), clamp (2), and J 44466-13 (1) to the fuel pipe and tighten. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4518 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. 15. Connect the J 44466-10 hose (1) to the J 44466-12 (3). 16. Install the J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter (1) or J 39021-302 V8 Fuel Injector Test Adapter to the metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank (3) must be refilled prior to performing this procedure. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verity the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. It an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat Steps 19, 20 and 21 for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off the pressure at the J 44466-10. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4519 25. Disconnect and remove the J 44466-10 (5) from the J 44466-12, and the J 41413. 26. Remove the J 39021-301 or J 39021-302, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install the brake booster vacuum hose and connector to the intake manifold. 29. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 30. Install the air inlet bonnet 10 the throttle body, tighten the wing-nut. 31. Install the PCV fresh air tube to the air inlet tube. 32. Obtain J 35800-A (2). Make sure the valve at the bottom of the canister (3) is closed. 33. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 34. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 35. Suspend J 35800-A from a convenient underhood location. 36. Connect the hose from J 35800-A to the service port on the J 44466-12 37. Open the valve (3) at the bottom of J 35800-A. 38. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 39. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 40. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 41. Remove the shop air supply from J 35800-A. 42. Depressurize the J 35800-A. 43. Disconnect the J 35800-A hose from the J 44466-12. 44. Remove the PCV clean air tube from the air inlet tube and set aside. 45. Remove the bonnet from the throttle body, and set aside. 46. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 47. Remove the brake booster vacuum hose and connector from the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4520 48. Bleed the residual pressure from the J 44466-12. 49. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body. 50. Remove J 44466-13 (1), clamp (2), and J 44466-11 (4), from the fuel pipe (3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4521 51. Install the fuel pipe (3) to the metering body. Make sure that all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. 52. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 53. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt (4). Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 54. Install the brake booster vacuum hose and connector to the intake manifold. 55. Install the bonnet and air inlet tube to the throttle body. 56. Install the PCV fresh air tube to the inlet duct. 57. Install ignition wires 1, 3, 5 (7) to the distributor cap. 58. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 59. Tighten the fuel tank filler cap. 60. Start the vehicle and check for fuel leaks. 61. Using the Tech 2(R) scan tool, check for any stored Powertrain DTC codes. Clear codes as required. 62. Disconnect the Tech 2(R) Scan tool. 63. Advise the customer to change brands of fuel. M/L, G Van and P Truck 1. Loosen the fuel tank filler cap to relieve fuel tank vapor pressure. 2. Remove the engine cover. 3. Remove ignition wires 1 3, 5, and 7 from the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4522 4. Remove the vacuum brake booster hose and connector from the intake manifold. 5. Remove the fuel pipe bolt (4) at the rear of the intake manifold. 6. Relieve the fuel system pressure at the service fitting on the fuel pipe. Use a shop towel to contain any fuel that may exit the service fitting. 7. Disconnect the fuel pipes (3) at the rear of intake manifold (1). 8. Remove the nuts (1) and clamp (2) from the fuel pipe. 9. Remove the fuel pipes from the metering body. Be careful not to disturb the 0-rings, washer, and spacer in the metering body. 10. Remove the electrical connector from metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4523 11. Install J 44466-12 (2) and J 44466-13 (1) to the fuel metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install J 44466-01 (1) to the vehicle fuel lines. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4524 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank must be refilled prior to performing this procedure. 15. Connect the J 44466-10 hose to the J 44466-12. 16. Install J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter or J 39021-302 V8 Fuel Injector Test Adapter to metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verify the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. If an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat steps 19, 20, and 21, for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off the pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off pressure at J 44466-10. 25. Disconnect and remove the J 44466-10 hose from the J 44466-12 and the J 41413. 26. Remove the J 39021-301 or J 39021-210, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 29. Install the vacuum brake booster hose and connector to the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4525 30. Obtain J 35800-A (2). Make sure the valve (3) at the bottom of the canister is closed. 31. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 32. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 33. Suspend the J 35800-A in a convenient location. 34. Connect the hose from the J 35800-A to the service port on the J 44466-12. 35. Open the valve (3) at the bottom of J 35800-A. 36. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 37. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 38. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 39. Remove the shop air supply from J 35800-A. 40. Depressurize the J 35800-A. 41. Disconnect the J 35800-A hose from the J 44466-12. 42. Remove the vacuum brake booster hose and connector from the intake manifold. 43. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 44. Bleed the residual pressure from J 44466-12. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4526 45. Remove the J 44466-13 (1) and J 44466-12 (2) from the metering body. 46. Remove the J 44466-01 (1) from the vehicle fuel lines. 47. Install the fuel pipe (3) to the metering body. Make sure the all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4527 48. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 49. Inspect the 0-rings at the fuel pipe-to-vehicle lines (1). Replace as necessary. Tighten Tighten the fuel line nuts to 30 N.m (22 lb ft). 50. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt. Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 51. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 52. Install the vacuum brake booster hose and connector to the intake manifold. 53. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 54. Tighten the fuel tank filler cap. 55. Start the engine and check for fuel leaks. 56. Use the Tech 2(R) Scan Tool to check for any stored Powertrain DTC codes. Clear codes as required. 57. Disconnect the Tech 2(R) Scan tool. 58. Install the engine cover. 59. Advise customer to change brands of fuel. Central SFI to MFI Conversion Instructions This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multiport Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). Important: Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4528 return for the same repair, then the CSFI unit can be replaced with a MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. V6 Engines 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket as shown in Figure 1. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 2. Tubes must be oriented away from the fuel pressure regulator end of the fuel meter body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4529 Notice: The number 3 Fuel Tube must be positioned behind the number 1 Fuel Tube to eliminate interference with the Upper Intake Manifold plenum when installed. See Figure 2. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Make sure that the number three Fuel Tube is routed in behind number 1 and 5 Fuel Tubes as shown in Figure 2. Push down firmly on the fuel meter body locking it into the bracket. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 5. Insert the number 3 injector into the correct Injector hole in the Lower Intake Manifold first. Install the number 5 injector next and then number 1. This sequence must be followed correctly to prevent interference of the Fuel Tubes. Injectors 2, 4, and 6 are then installed. 6. Insure that the electrical connectors of the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the Intake Manifold. If necessary, rotate the electrical connectors inboard. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 7. Lubricate the Fuel Meter Body Upper Manifold 0-ring (orange in color) with clean engine oil. 8. Inspect the Upper Intake Manifold plenum gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures outlined in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them into the Fuel Meter Body. Make sure that the Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4530 V8 Engines This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multipoint Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 3. Fuel tubes 1, 3, 5, and 7 are oriented toward the fuel inlet side of the fuel meter body. Fuel tubes 2, 4, 6, and 8 are oriented toward the fuel pressure regulator side if the fuel meter body. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Push down firmly on the fuel meter body until the tabs snap into the bracket locking the fuel meter body in place. 5. Orient the fuel tubes to coincide with their corresponding cylinder. The fuel tubes are numbered on the side of the fuel meter body and the corresponding cylinder number is cast in the intake manifold. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 6. Insert the fuel tubes into their corresponding holes in the intake manifold. Install tubes for cylinders 1, 3, 6 and 8 making sure that the injector electrical connectors are facing in toward the center of the manifold. 7. Insert fuel tubes for cylinders 2, 4, 5, and 7 in the same manner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4531 Important: When installing fuel tubes, it is important that the tubes are oriented properly to provide minimal interference when installing the upper intake manifold plenum. Intake holes for cylinders 2, 4, 5, and 7 are closer to the fuel meter body. It is necessary to cross tube 5 over tube 7 and tube 4 over tube 2 as shown in Figure 4. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 8. Lubricate the Fuel Meter Body Upper Manifold 0-ring (blue in color) with clean engine oil. 9. Inspect Upper Intake Manifold Gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them in the of the Fuel Meter Body. Make sure that Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed Fuel Injector: All Technical Service Bulletins Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4541 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4542 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4543 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4544 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up Technical Service Bulletin # 00-06-04-003B Date: 030201 Fuel System - MIL ON/Rough Idle on Start-Up File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-003B Date: February, 2003 TECHNICAL Subject: Rough Idle After Start, And/Or A Service Engine Soon (SES) Light (Unstick And Clean Central Sequential Fuel Injection (CSFI) Poppet Valves or Convert to MFI) Models: 1995-2002 Chevrolet and GMC S/T Models 1996-2002 Chevrolet and GMC C/K, M/L, G, P Models 1996-2001 Oldsmobile Bravada 1999-2000 Cadillac Escalade with 4.3L, 5.0L or 5.7L Engine (VINS W, X, M, R - RPOs L35, LF6, L30, L31) Except 2002 VIN X - RPO LU3 Models This bulletin is being revised to update the Warranty Information. Please discard previous copies of Corporate Bulletin Number 00-06-04-003B with warranty chart (Section 06 - Engine). This copy is for Dealers in the state of CALIFORNIA ONLY. Condition Some customers may comment on rough idle after start-up, especially if the vehicle has sat overnight. These symptoms may be intermittent. The Service Engine Soon (SES) light may also be illuminated. Current misfire or history misfire codes may be detected with the Tech 2 scan tool. Cause A deposit build-up on the CSFI poppet valve ball and/or seat may cause the poppet ball to stick open or closed. In either case, the specific cylinder will be mis-fueled, resulting in a cylinder mis-fire condition. Correction A new injector unsticking and cleaning process has proven to be effective in restoring poppet valves to an "as new" condition. CSFI injector replacement should NOT be considered as a correction for this customer concern. Check the vehicle history to determine if the vehicle is returning for a second fuel system repair for this condition. If the fuel system has been repaired for this condition previously, then inform the customer that an alternate fix is available. A new MFI fuel system has been developed that will back service the CSFI fuel system. The MFI fuel system eliminates the CSFI poppet valve ball and seat. The CSFI fuel system will need to be replaced as a unit. Refer to Central SFI to MFI Conversion instructions in this bulletin. Notice: Individual CSFI injectors can not be replaced with MFI injectors. The entire CSFI fuel meter body will need to be replaced. The bracket used to retain the injectors in the fuel meter body is different between the CSFI and MFI unit. The unit may not seal if you mix injectors. Severe engine damage could result. Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should return for the same repair, then the CSFI unit can be replaced with an MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. Important: "GM of Canada" dealers require District Service Manager approval prior to replacing the CSFI unit with a MFI unit under warranty. The first step of this process is to use the J 41413 Evap Pressure/Purge Station, in conjunction with the J 44466-10 pressure regulator/hose assembly, to provide the required high pressure (150 psi) source to perform the unsticking procedure. The J 39021 fuel injector tester and accessories provide the means to "energize" the injector. Some later model-year vehicles may utilize the Tech 2(R) to "energize" the injectors. The second step of this process is to run the engine on a solution of 10% Top Engine Cleaner and 90% gasoline. This will effectively clean any deposits from the ball and seats of the poppets. It is very important that the engine fuel system is separated from the vehicle fuel system. Top Engine Cleaner may have detrimental effects on the fuel pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4549 Parts Information Cleaning Procedure Parts CSFI to MFI Conversion Parts Parts are currently available from GMSPO. Warranty Information Important: Some California vehicles may be covered by Special Policy 99066E if built with California Emissions RPO YF5. If the vehicle is covered by the special policy, then that warranty information should be used. For vehicles repaired under warranty, use information contained in Special Policy 99066E. Information This procedure should be performed before any attempt to convert the fuel system to MFI. S/T and C/K Truck 1. Loosen the fuel filler cap to relieve vapor pressure in the fuel tank. 2. Remove the Positive Crankcase Ventilation (PCV) clean air tube from the air inlet tube and set aside. 3. Remove the bonnet and inlet tube from the throttle body. 4. Remove the brake booster vacuum hose and connector from the intake manifold. 5. Remove the electrical connector from the CSFI fuel metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4550 6. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 7. Remove the fuel line bolt (4) at the rear of the intake manifold. 8. Relieve the fuel system pressure at the service fitting on the fuel line. Use a shop towel to contain any fuel that may exit the service fitting. 9. Remove the nuts (1) and clamp (2) from the fuel pipe. 10. Remove the fuel pipes from the metering body. Be careful not to disturb the O-rings, washer, and spacer in the metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4551 11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install the J 44466-11 (4), clamp (2), and J 44466-13 (1) to the fuel pipe and tighten. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4552 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. 15. Connect the J 44466-10 hose (1) to the J 44466-12 (3). 16. Install the J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter (1) or J 39021-302 V8 Fuel Injector Test Adapter to the metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank (3) must be refilled prior to performing this procedure. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verity the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. It an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat Steps 19, 20 and 21 for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off the pressure at the J 44466-10. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4553 25. Disconnect and remove the J 44466-10 (5) from the J 44466-12, and the J 41413. 26. Remove the J 39021-301 or J 39021-302, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install the brake booster vacuum hose and connector to the intake manifold. 29. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 30. Install the air inlet bonnet 10 the throttle body, tighten the wing-nut. 31. Install the PCV fresh air tube to the air inlet tube. 32. Obtain J 35800-A (2). Make sure the valve at the bottom of the canister (3) is closed. 33. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 34. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 35. Suspend J 35800-A from a convenient underhood location. 36. Connect the hose from J 35800-A to the service port on the J 44466-12 37. Open the valve (3) at the bottom of J 35800-A. 38. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 39. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 40. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 41. Remove the shop air supply from J 35800-A. 42. Depressurize the J 35800-A. 43. Disconnect the J 35800-A hose from the J 44466-12. 44. Remove the PCV clean air tube from the air inlet tube and set aside. 45. Remove the bonnet from the throttle body, and set aside. 46. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 47. Remove the brake booster vacuum hose and connector from the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4554 48. Bleed the residual pressure from the J 44466-12. 49. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body. 50. Remove J 44466-13 (1), clamp (2), and J 44466-11 (4), from the fuel pipe (3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4555 51. Install the fuel pipe (3) to the metering body. Make sure that all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. 52. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 53. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt (4). Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 54. Install the brake booster vacuum hose and connector to the intake manifold. 55. Install the bonnet and air inlet tube to the throttle body. 56. Install the PCV fresh air tube to the inlet duct. 57. Install ignition wires 1, 3, 5 (7) to the distributor cap. 58. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 59. Tighten the fuel tank filler cap. 60. Start the vehicle and check for fuel leaks. 61. Using the Tech 2(R) scan tool, check for any stored Powertrain DTC codes. Clear codes as required. 62. Disconnect the Tech 2(R) Scan tool. 63. Advise the customer to change brands of fuel. M/L, G Van and P Truck 1. Loosen the fuel tank filler cap to relieve fuel tank vapor pressure. 2. Remove the engine cover. 3. Remove ignition wires 1 3, 5, and 7 from the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4556 4. Remove the vacuum brake booster hose and connector from the intake manifold. 5. Remove the fuel pipe bolt (4) at the rear of the intake manifold. 6. Relieve the fuel system pressure at the service fitting on the fuel pipe. Use a shop towel to contain any fuel that may exit the service fitting. 7. Disconnect the fuel pipes (3) at the rear of intake manifold (1). 8. Remove the nuts (1) and clamp (2) from the fuel pipe. 9. Remove the fuel pipes from the metering body. Be careful not to disturb the 0-rings, washer, and spacer in the metering body. 10. Remove the electrical connector from metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4557 11. Install J 44466-12 (2) and J 44466-13 (1) to the fuel metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install J 44466-01 (1) to the vehicle fuel lines. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4558 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank must be refilled prior to performing this procedure. 15. Connect the J 44466-10 hose to the J 44466-12. 16. Install J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter or J 39021-302 V8 Fuel Injector Test Adapter to metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verify the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. If an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat steps 19, 20, and 21, for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off the pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off pressure at J 44466-10. 25. Disconnect and remove the J 44466-10 hose from the J 44466-12 and the J 41413. 26. Remove the J 39021-301 or J 39021-210, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 29. Install the vacuum brake booster hose and connector to the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4559 30. Obtain J 35800-A (2). Make sure the valve (3) at the bottom of the canister is closed. 31. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 32. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 33. Suspend the J 35800-A in a convenient location. 34. Connect the hose from the J 35800-A to the service port on the J 44466-12. 35. Open the valve (3) at the bottom of J 35800-A. 36. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 37. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 38. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 39. Remove the shop air supply from J 35800-A. 40. Depressurize the J 35800-A. 41. Disconnect the J 35800-A hose from the J 44466-12. 42. Remove the vacuum brake booster hose and connector from the intake manifold. 43. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 44. Bleed the residual pressure from J 44466-12. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4560 45. Remove the J 44466-13 (1) and J 44466-12 (2) from the metering body. 46. Remove the J 44466-01 (1) from the vehicle fuel lines. 47. Install the fuel pipe (3) to the metering body. Make sure the all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4561 48. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 49. Inspect the 0-rings at the fuel pipe-to-vehicle lines (1). Replace as necessary. Tighten Tighten the fuel line nuts to 30 N.m (22 lb ft). 50. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt. Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 51. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 52. Install the vacuum brake booster hose and connector to the intake manifold. 53. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 54. Tighten the fuel tank filler cap. 55. Start the engine and check for fuel leaks. 56. Use the Tech 2(R) Scan Tool to check for any stored Powertrain DTC codes. Clear codes as required. 57. Disconnect the Tech 2(R) Scan tool. 58. Install the engine cover. 59. Advise customer to change brands of fuel. Central SFI to MFI Conversion Instructions This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multiport Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). Important: Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4562 return for the same repair, then the CSFI unit can be replaced with a MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. V6 Engines 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket as shown in Figure 1. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 2. Tubes must be oriented away from the fuel pressure regulator end of the fuel meter body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4563 Notice: The number 3 Fuel Tube must be positioned behind the number 1 Fuel Tube to eliminate interference with the Upper Intake Manifold plenum when installed. See Figure 2. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Make sure that the number three Fuel Tube is routed in behind number 1 and 5 Fuel Tubes as shown in Figure 2. Push down firmly on the fuel meter body locking it into the bracket. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 5. Insert the number 3 injector into the correct Injector hole in the Lower Intake Manifold first. Install the number 5 injector next and then number 1. This sequence must be followed correctly to prevent interference of the Fuel Tubes. Injectors 2, 4, and 6 are then installed. 6. Insure that the electrical connectors of the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the Intake Manifold. If necessary, rotate the electrical connectors inboard. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 7. Lubricate the Fuel Meter Body Upper Manifold 0-ring (orange in color) with clean engine oil. 8. Inspect the Upper Intake Manifold plenum gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures outlined in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them into the Fuel Meter Body. Make sure that the Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4564 V8 Engines This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multipoint Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 3. Fuel tubes 1, 3, 5, and 7 are oriented toward the fuel inlet side of the fuel meter body. Fuel tubes 2, 4, 6, and 8 are oriented toward the fuel pressure regulator side if the fuel meter body. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Push down firmly on the fuel meter body until the tabs snap into the bracket locking the fuel meter body in place. 5. Orient the fuel tubes to coincide with their corresponding cylinder. The fuel tubes are numbered on the side of the fuel meter body and the corresponding cylinder number is cast in the intake manifold. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 6. Insert the fuel tubes into their corresponding holes in the intake manifold. Install tubes for cylinders 1, 3, 6 and 8 making sure that the injector electrical connectors are facing in toward the center of the manifold. 7. Insert fuel tubes for cylinders 2, 4, 5, and 7 in the same manner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4565 Important: When installing fuel tubes, it is important that the tubes are oriented properly to provide minimal interference when installing the upper intake manifold plenum. Intake holes for cylinders 2, 4, 5, and 7 are closer to the fuel meter body. It is necessary to cross tube 5 over tube 7 and tube 4 over tube 2 as shown in Figure 4. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 8. Lubricate the Fuel Meter Body Upper Manifold 0-ring (blue in color) with clean engine oil. 9. Inspect Upper Intake Manifold Gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them in the of the Fuel Meter Body. Make sure that Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 04-06-04-051B > Jan > 06 > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: All Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up Technical Service Bulletin # 00-06-04-003B Date: 030201 Fuel System - MIL ON/Rough Idle on Start-Up File In Section: 06 - Engine/Propulsion System Bulletin No.: 00-06-04-003B Date: February, 2003 TECHNICAL Subject: Rough Idle After Start, And/Or A Service Engine Soon (SES) Light (Unstick And Clean Central Sequential Fuel Injection (CSFI) Poppet Valves or Convert to MFI) Models: 1995-2002 Chevrolet and GMC S/T Models 1996-2002 Chevrolet and GMC C/K, M/L, G, P Models 1996-2001 Oldsmobile Bravada 1999-2000 Cadillac Escalade with 4.3L, 5.0L or 5.7L Engine (VINS W, X, M, R - RPOs L35, LF6, L30, L31) Except 2002 VIN X - RPO LU3 Models This bulletin is being revised to update the Warranty Information. Please discard previous copies of Corporate Bulletin Number 00-06-04-003B with warranty chart (Section 06 - Engine). This copy is for Dealers in the state of CALIFORNIA ONLY. Condition Some customers may comment on rough idle after start-up, especially if the vehicle has sat overnight. These symptoms may be intermittent. The Service Engine Soon (SES) light may also be illuminated. Current misfire or history misfire codes may be detected with the Tech 2 scan tool. Cause A deposit build-up on the CSFI poppet valve ball and/or seat may cause the poppet ball to stick open or closed. In either case, the specific cylinder will be mis-fueled, resulting in a cylinder mis-fire condition. Correction A new injector unsticking and cleaning process has proven to be effective in restoring poppet valves to an "as new" condition. CSFI injector replacement should NOT be considered as a correction for this customer concern. Check the vehicle history to determine if the vehicle is returning for a second fuel system repair for this condition. If the fuel system has been repaired for this condition previously, then inform the customer that an alternate fix is available. A new MFI fuel system has been developed that will back service the CSFI fuel system. The MFI fuel system eliminates the CSFI poppet valve ball and seat. The CSFI fuel system will need to be replaced as a unit. Refer to Central SFI to MFI Conversion instructions in this bulletin. Notice: Individual CSFI injectors can not be replaced with MFI injectors. The entire CSFI fuel meter body will need to be replaced. The bracket used to retain the injectors in the fuel meter body is different between the CSFI and MFI unit. The unit may not seal if you mix injectors. Severe engine damage could result. Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should return for the same repair, then the CSFI unit can be replaced with an MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. Important: "GM of Canada" dealers require District Service Manager approval prior to replacing the CSFI unit with a MFI unit under warranty. The first step of this process is to use the J 41413 Evap Pressure/Purge Station, in conjunction with the J 44466-10 pressure regulator/hose assembly, to provide the required high pressure (150 psi) source to perform the unsticking procedure. The J 39021 fuel injector tester and accessories provide the means to "energize" the injector. Some later model-year vehicles may utilize the Tech 2(R) to "energize" the injectors. The second step of this process is to run the engine on a solution of 10% Top Engine Cleaner and 90% gasoline. This will effectively clean any deposits from the ball and seats of the poppets. It is very important that the engine fuel system is separated from the vehicle fuel system. Top Engine Cleaner may have detrimental effects on the fuel pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4575 Parts Information Cleaning Procedure Parts CSFI to MFI Conversion Parts Parts are currently available from GMSPO. Warranty Information Important: Some California vehicles may be covered by Special Policy 99066E if built with California Emissions RPO YF5. If the vehicle is covered by the special policy, then that warranty information should be used. For vehicles repaired under warranty, use information contained in Special Policy 99066E. Information This procedure should be performed before any attempt to convert the fuel system to MFI. S/T and C/K Truck 1. Loosen the fuel filler cap to relieve vapor pressure in the fuel tank. 2. Remove the Positive Crankcase Ventilation (PCV) clean air tube from the air inlet tube and set aside. 3. Remove the bonnet and inlet tube from the throttle body. 4. Remove the brake booster vacuum hose and connector from the intake manifold. 5. Remove the electrical connector from the CSFI fuel metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4576 6. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 7. Remove the fuel line bolt (4) at the rear of the intake manifold. 8. Relieve the fuel system pressure at the service fitting on the fuel line. Use a shop towel to contain any fuel that may exit the service fitting. 9. Remove the nuts (1) and clamp (2) from the fuel pipe. 10. Remove the fuel pipes from the metering body. Be careful not to disturb the O-rings, washer, and spacer in the metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4577 11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install the J 44466-11 (4), clamp (2), and J 44466-13 (1) to the fuel pipe and tighten. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4578 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. 15. Connect the J 44466-10 hose (1) to the J 44466-12 (3). 16. Install the J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter (1) or J 39021-302 V8 Fuel Injector Test Adapter to the metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank (3) must be refilled prior to performing this procedure. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verity the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. It an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat Steps 19, 20 and 21 for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off the pressure at the J 44466-10. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4579 25. Disconnect and remove the J 44466-10 (5) from the J 44466-12, and the J 41413. 26. Remove the J 39021-301 or J 39021-302, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install the brake booster vacuum hose and connector to the intake manifold. 29. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 30. Install the air inlet bonnet 10 the throttle body, tighten the wing-nut. 31. Install the PCV fresh air tube to the air inlet tube. 32. Obtain J 35800-A (2). Make sure the valve at the bottom of the canister (3) is closed. 33. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 34. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 35. Suspend J 35800-A from a convenient underhood location. 36. Connect the hose from J 35800-A to the service port on the J 44466-12 37. Open the valve (3) at the bottom of J 35800-A. 38. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 39. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 40. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 41. Remove the shop air supply from J 35800-A. 42. Depressurize the J 35800-A. 43. Disconnect the J 35800-A hose from the J 44466-12. 44. Remove the PCV clean air tube from the air inlet tube and set aside. 45. Remove the bonnet from the throttle body, and set aside. 46. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 47. Remove the brake booster vacuum hose and connector from the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4580 48. Bleed the residual pressure from the J 44466-12. 49. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body. 50. Remove J 44466-13 (1), clamp (2), and J 44466-11 (4), from the fuel pipe (3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4581 51. Install the fuel pipe (3) to the metering body. Make sure that all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. 52. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 53. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt (4). Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 54. Install the brake booster vacuum hose and connector to the intake manifold. 55. Install the bonnet and air inlet tube to the throttle body. 56. Install the PCV fresh air tube to the inlet duct. 57. Install ignition wires 1, 3, 5 (7) to the distributor cap. 58. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 59. Tighten the fuel tank filler cap. 60. Start the vehicle and check for fuel leaks. 61. Using the Tech 2(R) scan tool, check for any stored Powertrain DTC codes. Clear codes as required. 62. Disconnect the Tech 2(R) Scan tool. 63. Advise the customer to change brands of fuel. M/L, G Van and P Truck 1. Loosen the fuel tank filler cap to relieve fuel tank vapor pressure. 2. Remove the engine cover. 3. Remove ignition wires 1 3, 5, and 7 from the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4582 4. Remove the vacuum brake booster hose and connector from the intake manifold. 5. Remove the fuel pipe bolt (4) at the rear of the intake manifold. 6. Relieve the fuel system pressure at the service fitting on the fuel pipe. Use a shop towel to contain any fuel that may exit the service fitting. 7. Disconnect the fuel pipes (3) at the rear of intake manifold (1). 8. Remove the nuts (1) and clamp (2) from the fuel pipe. 9. Remove the fuel pipes from the metering body. Be careful not to disturb the 0-rings, washer, and spacer in the metering body. 10. Remove the electrical connector from metering body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4583 11. Install J 44466-12 (2) and J 44466-13 (1) to the fuel metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position. 12. Install J 44466-01 (1) to the vehicle fuel lines. 13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4584 14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank must be refilled prior to performing this procedure. 15. Connect the J 44466-10 hose to the J 44466-12. 16. Install J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter or J 39021-302 V8 Fuel Injector Test Adapter to metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. 20. Close the valve (4) on the J 44466-10. 21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verify the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. If an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational. 22. Repeat steps 19, 20, and 21, for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional. 23. Shut off the pressure valve (2) on the tank (3) of the J 41413. 24. Bleed off pressure at J 44466-10. 25. Disconnect and remove the J 44466-10 hose from the J 44466-12 and the J 41413. 26. Remove the J 39021-301 or J 39021-210, J 39021-210, and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 29. Install the vacuum brake booster hose and connector to the intake manifold. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4585 30. Obtain J 35800-A (2). Make sure the valve (3) at the bottom of the canister is closed. 31. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister. 32. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 33. Suspend the J 35800-A in a convenient location. 34. Connect the hose from the J 35800-A to the service port on the J 44466-12. 35. Open the valve (3) at the bottom of J 35800-A. 36. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi. 37. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi. 38. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 39. Remove the shop air supply from J 35800-A. 40. Depressurize the J 35800-A. 41. Disconnect the J 35800-A hose from the J 44466-12. 42. Remove the vacuum brake booster hose and connector from the intake manifold. 43. Remove ignition wires 1, 3, 5, and 7 from the distributor cap. 44. Bleed the residual pressure from J 44466-12. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4586 45. Remove the J 44466-13 (1) and J 44466-12 (2) from the metering body. 46. Remove the J 44466-01 (1) from the vehicle fuel lines. 47. Install the fuel pipe (3) to the metering body. Make sure the all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4587 48. Install the clamp (2) and nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in). 49. Inspect the 0-rings at the fuel pipe-to-vehicle lines (1). Replace as necessary. Tighten Tighten the fuel line nuts to 30 N.m (22 lb ft). 50. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt. Install the bolt. Tighten Tighten the fuel pipe bolt to 6 N.m (53 lb in). 51. Install ignition wires 1, 3, 5, and 7 to the distributor cap. 52. Install the vacuum brake booster hose and connector to the intake manifold. 53. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km). 54. Tighten the fuel tank filler cap. 55. Start the engine and check for fuel leaks. 56. Use the Tech 2(R) Scan Tool to check for any stored Powertrain DTC codes. Clear codes as required. 57. Disconnect the Tech 2(R) Scan tool. 58. Install the engine cover. 59. Advise customer to change brands of fuel. Central SFI to MFI Conversion Instructions This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multiport Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). Important: Cleaning the CSFI injectors is the preferred repair. The CSFI unit should not be replaced until cleaning has been attempted. If the vehicle should Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4588 return for the same repair, then the CSFI unit can be replaced with a MFI unit. If the vehicle is out of warranty, the customer should be given the option of which fix to pursue. V6 Engines 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket as shown in Figure 1. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 2. Tubes must be oriented away from the fuel pressure regulator end of the fuel meter body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4589 Notice: The number 3 Fuel Tube must be positioned behind the number 1 Fuel Tube to eliminate interference with the Upper Intake Manifold plenum when installed. See Figure 2. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Make sure that the number three Fuel Tube is routed in behind number 1 and 5 Fuel Tubes as shown in Figure 2. Push down firmly on the fuel meter body locking it into the bracket. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 5. Insert the number 3 injector into the correct Injector hole in the Lower Intake Manifold first. Install the number 5 injector next and then number 1. This sequence must be followed correctly to prevent interference of the Fuel Tubes. Injectors 2, 4, and 6 are then installed. 6. Insure that the electrical connectors of the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the Intake Manifold. If necessary, rotate the electrical connectors inboard. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 7. Lubricate the Fuel Meter Body Upper Manifold 0-ring (orange in color) with clean engine oil. 8. Inspect the Upper Intake Manifold plenum gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures outlined in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them into the Fuel Meter Body. Make sure that the Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4590 V8 Engines This procedure outlines the steps required to replace the existing Central SFI Fuel System with a new MFI (Multipoint Flexible Injection) Fuel System. Be sure to use the appropriate year and model Service Manual for proper disassembly and re-assembly procedure(s). 1. Remove Upper Intake Manifold plenum and SFI Fuel Meter Body according to Service Manual Procedures. 2. Remove the Fuel Meter Body bracket and discard. Install the new bracket. 3. Position Fuel Tubes of MFI Fuel Meter Body as shown in Figure 3. Fuel tubes 1, 3, 5, and 7 are oriented toward the fuel inlet side of the fuel meter body. Fuel tubes 2, 4, 6, and 8 are oriented toward the fuel pressure regulator side if the fuel meter body. 4. Insert the MFI Fuel Meter Body into the Fuel Meter Body Bracket on the Lower Intake Manifold being careful not to bind the Fuel Tubes. Push down firmly on the fuel meter body until the tabs snap into the bracket locking the fuel meter body in place. 5. Orient the fuel tubes to coincide with their corresponding cylinder. The fuel tubes are numbered on the side of the fuel meter body and the corresponding cylinder number is cast in the intake manifold. Notice: Use caution when inserting injectors into lower intake manifold to be sure the correct injector is being placed into the correct hole. Injectors should not be removed once they have been installed. Removal of injectors from the intake manifold may cause damage to the retaining lugs on the injector. Important: The Injector holes are numbered on the Lower Intake Manifold. The injectors are numbered on the side of the Fuel Meter Body. 6. Insert the fuel tubes into their corresponding holes in the intake manifold. Install tubes for cylinders 1, 3, 6 and 8 making sure that the injector electrical connectors are facing in toward the center of the manifold. 7. Insert fuel tubes for cylinders 2, 4, 5, and 7 in the same manner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 00-06-04-003B > Feb > 03 > Fuel System - MIL ON/Rough Idle on Start-Up > Page 4591 Important: When installing fuel tubes, it is important that the tubes are oriented properly to provide minimal interference when installing the upper intake manifold plenum. Intake holes for cylinders 2, 4, 5, and 7 are closer to the fuel meter body. It is necessary to cross tube 5 over tube 7 and tube 4 over tube 2 as shown in Figure 4. Notice: Lack of lubrication will make installation of the Upper Intake Manifold plenum difficult and may cause damage to the 0-ring. 8. Lubricate the Fuel Meter Body Upper Manifold 0-ring (blue in color) with clean engine oil. 9. Inspect Upper Intake Manifold Gasket and replace if necessary. Reinstall the Upper Intake Manifold plenum following the procedures in the Service Manual. Important: Lubricate the Fuel Inlet and Return Lines with clean engine oil before inserting them in the of the Fuel Meter Body. Make sure that Fuel Line Retaining Bracket is properly oriented with the tabs down. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed Fuel Injector: All Technical Service Bulletins Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4601 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4602 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4603 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4604 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Resistance Ohms Resistance Ohms ECT between 50 - 90degrees F (10 - 32 degrees C) Ohms 11.0-14.0 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 4607 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop Fuel Injector Pressure Drop If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly. Pressure Drop 1.5 psi Fuel Injector Balance Test Example (Typical) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4612 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Fuel Injector: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Central Sequential Fuel Injection (CSFI) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4642 Fuel Injector: Description and Operation The Multec 2 fuel injector assembly is a solenoid device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid to open a normally closed ball valve. This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test CIRCUIT DESCRIPTION The powertrain control module (PCM) enables the appropriate fuel injector on the intake stroke for each cylinder. A voltage is supplied directly to the fuel injectors. The PCM controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS ^ Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. ^ Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. ^ Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. ^ If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4645 Steps 1-7 The numbers below refer to the step numbers on the diagnostic table. 3. This step tests each fuel injector resistance within a specific temperature range. If any of the fuel injectors display a resistance outside of the specified value, replace the fuel injector. 4. This step determines if all of the fuel injectors are within 3 ohms of each other. If the highest resistance value is within 3 ohms of the lowest resistance value, then all of the fuel injector coil windings are OK. 5. This step determines which fuel injector is faulty. After subtracting the highest and lowest resistance values from the average value, replace the fuel injector that has the greatest resistance difference from the average. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4646 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool CIRCUIT Fuel Injector Balance Test With Special Tool Fuel Injector Balance Test Example (Typical) TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4647 Steps 1-5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4648 Steps 6-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Refer to the Fuel Injector Balance Test Example. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4649 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 CIRCUIT DESCRIPTION The scan tool first energizes the fuel pump and then the injectors for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4650 Steps 6-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 4. The fuel pressure should be within the specified range. Refer to Fuel System Diagnosis if the fuel pressure is not within the specified range. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 5. The fuel pressure should reach a steady value. Refer to Fuel System Diagnosis if the fuel pressure does not stabilize. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Calculate the pressure drop value for each fuel injector by subtracting the second pressure reading from the first pressure reading. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4651 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis CIRCUIT DESCRIPTION The powertrain control module (PCM) enables the appropriate fuel injector on the intake stroke for each cylinder. A voltage is supplied directly to the fuel injectors. The PCM controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS ^ Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help isolate an intermittent condition. ^ Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics ^ For an intermittent condition refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1-7 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 4652 Steps 8-12 The numbers below refer to the step numbers on the diagnostic table. 4. This step tests for a short to ground on the ignition 1 voltage supply circuit of the fuel injector. 5. This step tests for a short to a PCM ground on the ignition 1 voltage supply circuit of the fuel injector. 6. This step tests for an open ignition 1 voltage supply circuit between the ECM 1 fuse and the multi-way connector. 7. This step tests for high resistance between the ECM 1 fuse and the multi-way connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 4653 Fuel Injector: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the upper intake manifold assembly. 3. Remove the fuel meter body assembly (1). 4. Remove the injector assembly retainer (4) and the injector retainer lock nuts (2). NOTE: Use care in removing the fuel injectors to prevent damage to the electrical connector terminals. The fuel injector is serviced as a complete assembly only. Also since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector cleaning is not recommended. 5. While pulling the injector tube downward, push with a small tip punch down between the injector terminals until the injector (3) is removed. INSTALLATION PROCEDURE IMPORTANT: Each injector is calibrated for a specific flow rate. Order the correct injector for the application being serviced when replacing the fuel injectors. 1. Lubricate the O-ring seals with engine oil on the new fuel injector assembly (3). 2. Install the fuel injector assembly (3) into the fuel meter body (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 4654 3. Install the injector assembly retainer (4) and the injector retainer lock nuts (2). Tighten Tighten the injector retainer lock nuts to 3 N.m (27 lb in). 4. Install the fuel meter body assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOLS REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. 5. Pull the connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 4660 INSTALLATION PROCEDURE CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 4661 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief Procedure. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. Squeeze the plastic retainer release tabs. 4. Pull the connection apart. INSTALLATION PROCEDURE CAUTION: Always apply a few drops Of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located In the female connector will swell and may prevent proper reconnection If not lubricated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 4662 1. Apply a few drops of clean engine oil to the male fuel pipe end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation Fuel Meter Body: Description and Operation FUEL METER BODY ASSEMBLY The fuel meter body assembly attaches to the lower intake manifold. The fuel meter body assembly performs the following functions: ^ Distributes fuel evenly to the injectors ^ Integrates the fuel pressure regulator into the fuel metering system Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation > Page 4666 Fuel Meter Body: Service and Repair FUEL METER BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE An 8 digit part identification number is on a mylar label affixed to the fuel meter body assembly. Refer to this number if servicing or part replacement is required. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the upper intake manifold assembly. NOTE: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Before removal, clean the fuel meter body assembly with a spray type engine cleaner, GM X-30A, if necessary. Follow the package instructions. Do not soak fuel meter body assemblies in liquid cleaning solvent. NOTE: Cover the injector sockets in order to prevent dirt and other contaminants from entering the open fuel passages. IMPORTANT: When disconnecting the injectors, remember the sequence in order to ensure correct injector placement to each cylinder. 4. Squeeze the injector locking tabs together while lining the injector out of the casting socket. 5. Remove the fuel meter body from the bracket by releasing the lock tabs on the bracket. INSTALLATION PROCEDURE 1. Install the MFI fuel meter body into the bracket on the lower intake manifold. Place all of the fuel tubes in a forward position. Route the number 3 fuel tube behind the numbers 1 and 5 fuel tubes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Meter Body > Component Information > Description and Operation > Page 4667 CAUTION: Verify that the injectors are firmly seated and locked in their casting sockets, in order to reduce the risk of fire and personal injury. An unlocked or a loose injector could work loose from its socket and produce a fuel leak. If an injector is loose, replace the retainer. IMPORTANT: The fuel meter body assembly and the lower intake are numbered to indicate correct injector order. Ensure that the electrical connectors on the injectors do not interfere with each other and point towards the center of the intake manifold. Rotate the electrical connectors inboard, if necessary. 2. Insert the 6 injectors in the following sequence: 2.1. Insert #3 injector into the #3 injector hole. 2.2. Insert #5 injector into the #5 injector hole. 2.3. Insert #1 injector into the #1 injector hole. 2.4. Insert #2 injector into the #2 injector hole. 2.5. Insert #4 injector into the #4 injector hole. 2.6. Insert #6 injector into the #6 injector hole. 3. Install the upper intake manifold assembly. 4. Connect the negative battery cable. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition. 5.4. Inspect for fuel leaks. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY Fuel Pressure Regulator Assembly The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the fuel injectors under all operating conditions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 4671 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Computers and Controls Systems. 2. Remove the upper intake manifold assembly. 3. Remove the fuel pressure regulator retainer clip (5). 4. Pull and twist the fuel pressure regulator (6) in order to remove the fuel pressure regulator from the fuel pressure regulator housing using a shop towel to catch any spilled fuel. 5. Remove the regulator seal lower O-ring (3). 6. Remove the regulator assembly filter (2). 7. Remove the regulator seal upper O-ring (1). 8. Remove the regulator seal backup ring (7). 9. Discard the O-rings. INSTALLATION PROCEDURE IMPORTANT: If the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If the filter screen is contaminated, replace the regulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 4672 1. Lubricate the new O-rings with clean engine oil. 2. Install the regulator seal backup ring (7). 3. Install the regulator seal upper O-ring (1). 4. Install the regulator assembly filter (2). 5. Install the regulator seal lower O-ring (3). 6. Assemble the regulator (6) with the vacuum tube pointing down into the regulator retainer clip. 7. Install the fuel pressure regulator retainer clip (5). 8. Install the upper manifold assembly. 9. Connect the negative battery cable. 10. Inspect for leaks. 10.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 10.2. Turn OFF the ignition for 10 seconds. 10.3. Turn ON the ignition, with the engine OFF. 10.4. Inspect for fuel leaks. 11. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 4720 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Note the position of the fuel strainer (2) on the fuel sender. 3. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand. 4. Pull the strainer off the fuel sender. Discard the strainer after inspection. 5. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank. INSTALLATION PROCEDURE 1. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated. 2. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel meter body assembly. The fuel return pipe carries fuel from the fuel meter body assembly back to the fuel tank. The fuel pipes consist of 2 sections: ^ The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. ^ The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel meter body. These pipes are constructed of steel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the air cleaner outlet resonator. 3. Disconnect the left bank spark plug wires from the distributor. 4. Disconnect the fuel pipes at the rear of the intake manifold. 5. Remove the injector fuel inlet and outlet pipe retainer nuts. 6. Remove the injector fuel inlet and the outlet pipe retainer. 7. Remove the rear fuel pipe bracket retaining bolt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4728 8. Pull straight up on the fuel pipes in order to remove the fuel pipes from the fuel meter body. 9. Remove the O-ring seals from both ends of the fuel feed and return pipes. 10. Discard the O-ring seals. INSTALLATION PROCEDURE 1. Assemble the new O-rings into the inlet and outlet of the fuel meter body. CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 2. Apply a few drops of clean engine oil to the male tube ends. 3. Install the fuel feed and return pipes to the fuel meter body. 4. Install the fuel pipe retainer and the attaching nuts. Once installed, pull on both ends of each connection in order to make sure they are secure. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4729 5. Install the rear fuel pipe bracket retaining bolt. Tighten 5.1. Tighten the rear fuel pipe bracket bolt to 6 N.m (53 lb in). 5.2. Tighten the fuel pipe retainer nuts to 3 N.m (27 lb in). 6. Install the new O-ring seals on the engine fuel feed and the return pipes. 7. Connect the fuel feed and return pipes to the engine fuel pipes. Tighten Tighten the fuel pipe fittings to 30 N.m (22 lb ft). 8. Connect the negative battery cable. 9. Inspect for fuel leaks. 9.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 9.2. Turn OFF the ignition for 10 seconds. 9.3. Turn ON the ignition, with the engine OFF. 9.4. Inspect for fuel leaks. 10. Connect the left bank spark plug wires to the distributor. 11. Install the air cleaner outlet resonator. 12. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4730 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Front) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system. 3. Disconnect the fuel feed and return pipes (8) from the engine compartment fuel pipes. 4. Cap the engine compartment fuel pipes. 5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Remove the fuel pipes retainer mounting stud (7) from the cylinder head. 7. Remove the fuel pipes retainer mounting stud (6) from the transmission. 8. Remove the fuel pipes retainer mounting fastener (5) from the crossrail. 9. Disconnect the fuel return pipe (2) at the coupler (3). 10. Disconnect the fuel feed pipe at the fuel filter outlet. 11. Cap the rear fuel pipes. 12. Note the position of the fuel pipes for aid in installation. 13. Remove the fuel pipes from the retaining clips. 14. Remove the fuel pipes. INSTALLATION PROCEDURE IMPORTANT: ^ When replacing the fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4731 replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection. ^ Do not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required. 1. Remove the caps from the rear fuel pipes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Connect the chassis fuel feed pipe at the fuel filter outlet. Tighten Tighten the fuel feed pipe fitting to 30 N.m (22 lb ft). 3. Connect the fuel return pipe (2) at the coupler (3). Tighten Tighten the return pipe fitting to 27 N.m (20 lb ft). 4. Install the fuel pipes into the transmission bracket retainer. 5. Install the mounting stud (6). Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 6. Install the fuel pipes into the cylinder head retainer. 7. Install the mounting stud (7). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4732 Tighten Tighten the mounting stud to 33 N.m (24 lb ft). 8. Install the fuel pipes into the crossrail retainer. 9. Install the mounting bolt (5) to the crossrail. Tighten Tighten the mounting bolt to 11 N.m (97 lb in). 10. Lower the vehicle. 11. Remove the caps from the engine compartment fuel pipes. 12. Connect the fuel feed and return pipes (8) to the engine compartment fuel pipes. Ensure the O-rings are in place. Tighten Tighten the fuel feed and return pipe fittings to 30 N.m (22 lb ft). 13. Connect the negative battery cable. 14. Inspect for leaks. 14.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 14.2. Turn OFF the ignition for 10 seconds. 14.3. Turn ON the ignition, with the engine OFF. 14.4. Inspect for fuel leaks. 15. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4733 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Rear) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the front fuel pipes (3) from the rear chassis pipes (1). 3. Drain gasoline into an approved container. 4. Disconnect the fuel feed pipe (1) from the fuel filter. 5. Discard the O-ring. 6. Disconnect the fuel return pipe (2) from the coupler (3). 7. Discard the O-ring. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4734 8. Disconnect the fuel return (5) and the fuel feed (2) pipes from the fuel tank pipes (1). 9. Release the fuel pipe grommet (4) from the crossrail. 10. Remove the fuel pipe retainer (3) from the crossrail. 11. Release the fuel pipes from the retainer and the grommet. INSTALLATION PROCEDURE CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 1. Install the new O-rings on the engine fuel feed and return pipes. 2. Position the fuel pipes into the crossrail retainer and the crossrail grommet. 3. Position the new fuel pipes through the crossrails in the original location. 4. Loosely assemble the fuel feed pipe (1) to the fuel filter. 5. Loosely assemble the fuel return pipe (2) to the coupler (3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4735 6. Install the fuel pipe grommet (4) into the crossrail. Lubricate the grommet to aid in the installation. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the fuel pipe retainer to the crossrail. Tighten ^ Tighten the fuel pipe crossrail retainer to 11 N.m (97 lb in). ^ Tighten the fuel feed pipe to fuel filter fitting to 27 N.m (20 lb ft) using a back-up wrench. ^ Tighten the fuel return pipe to coupler fitting to 27 N.m (20 lb ft) using a back-up wrench. 8. Apply a few drops of clean engine oil to the rear male connector pipe ends. 9. Connect the fuel return (5) and the fuel feed (2) pipes to the fuel tank pipes (1). 10. Connect the negative battery cable. 11. Inspect for fuel leaks. 11.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 11.2. Turn OFF the ignition for 10 seconds. 11.3. Turn ON the ignition, with the engine OFF. 11.4. Inspect for fuel leaks. 12. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 4736 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Assembly Replacement REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Remove the fuel pipes (1) from the fuel sender (2). INSTALLATION PROCEDURE CAUTION: Refer to Fuel Pipe Fitting Caution in Service Precautions. 1. Install fuel pipes (1) to the fuel sender (2). 2. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed Fuel Filler Hose: Recalls Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4746 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4747 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4748 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4749 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed Fuel Filler Hose: All Technical Service Bulletins Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4755 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4756 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4757 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4758 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4759 Fuel Filler Hose: Description and Operation FUEL FILL PIPE The fuel fill pipe has a built-in restrictor and a deflector in order to prevent refueling with leaded fuel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement Fuel Filler Hose: Service and Repair Filler Tube Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the fuel tank to a level below that of the fuel tank filler tube. Refer to Fuel Tank Draining Procedure. 3. Remove the fuel filler tube to the fuel filler pocket screws (1). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Wipe the fuel filler tube connection at the fuel tank with a clean cloth and then disconnect the fuel filler tube clamp (3). 6. Remove the fuel fill tube attaching screw (2) and the fuel filler tube. INSTALLATION PROCEDURE 1. Install the fuel filler tube into the fuel tank. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel filler tube attaching screw (2). Tighten Tighten the attaching screw to 11.5 N.m (102 lb in). 3. Connect the fuel filler tube hose and clamp (3). Tighten Tighten the fuel fill hose clamp to 3 N.m (27 lb in). 4. Install the fuel filler tube screws at the fuel filler pocket. Tighten Tighten the fuel filler tube screws to 1.9 N.m (17 lb in). 5. Connect the negative battery cable. 6. Refill the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 4762 7. Inspect for fuel leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Filler Tube Replacement > Page 4763 Fuel Filler Hose: Service and Repair Fuel Filler Hose Replacement REMOVAL PROCEDURE 1. Remove the fuel filler tube. 2. Disconnect the fuel fill hose from the fuel fill tube. 3. Remove the fuel fill hose and the hose clamps (3). 4. Cap the fuel tank opening. INSTALLATION PROCEDURE 1. Uncap the fuel tank opening. 2. Install the fuel fill hose and the hose clamps (3) on to the filler tube. 3. Install the fuel filler tube. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed Fuel Filler Neck: Recalls Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4772 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4773 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4774 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Recalls for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign Fuel Injector Sticking Closed > Page 4775 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed Fuel Filler Neck: All Technical Service Bulletins Campaign - Fuel Injector Sticking Closed File In Section: 06-Engine Emissions Bulletin No.: 99066F Date: March, 2003 SPECIAL POLICY SUBJECT: 99066F - SPECIAL POLICY ADJUSTMENT - SEQUENTIAL CENTRAL PORT FUEL INJECTION (SCPI) FAILURES IN CALIFORNIA ONLY (YF5 EMISSION EQUIPPED) MODELS: CERTAIN 1996, 1997, 1998, 1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR TRUCKS AND 2003 NPR TRUCKS EQUIPPED WITH 4.3L (RPO L35 - VIN CODE W OR RPO LF6 - VIN CODE X), 5.0L (RPO L30 - VIN CODE M) OR 5.7L (RPO L31 - VIN CODE R) ENGINE AND CALIFORNIA EMISSION EQUIPPED (RPO YF5) This bulletin is being revised to add the 2002 and 2003 model years to the SCPI Special Policy on certain S/T, M/L, C/K, G, P and W4/NPR truck models. Please discard Special Policy Bulletin Number 99066E, dated February, 2003. CONDITION Some customers of 1996, 1997, 1998, 1999, 2000, 2001, 2002 model year S/T, M/L, C/K, G, P, W4/NPR trucks and 2003 NPR trucks, that are registered in California, equipped with 4.3L (RPO L35 and VIN Code W, or RPO LF6 and VIN Code X), 5.0L (RPO L30 and VIN Code M) or 5.7L (RPO L31 and VIN Code R) engine, and California emissions (RPO YF5), may experience a "Service Engine Soon" light, misfire, rough idle or hard start due to a deposit build-up on the Sequential Central Port Fuel Injector (SCPI) poppet valve(s). The deposit build-up may cause injector poppets to stick closed. Certain fuels have been found to interact with the SCPI system to cause the deposits. SPECIAL POLICY ADJUSTMENT This special policy covers the SCPI failure condition described above for a period of ten (10) years or 200,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring SCPI system servicing, injector cleaning and/or MFI assembly replacement of the SCPI system. The customer should not be charged for performing a system check when it is determined that the SCPI system is not the cause of a customer complaint (labor operation T5532 is provided to submit claims for such system checks). Any additional necessary diagnosis and repairs that are not related to the SCPI condition are not covered by this special policy. The customer should be informed that any further service that is not covered by new vehicle warranty will not be covered by this policy. VEHICLES INVOLVED Involved are certain 1996,1997,1998,1999, 2000, 2001, 2002 S/T, M/L, C/K, G, P, W4/NPR and 2003 NPR model vehicles, registered in California, equipped with 4.3L (RPO L35 - VIN Code W, or RPO LF6 - VIN Code X), 5.0L (RPO L30 - VIN Code M) or 5.7L (RPO L31 - VIN Code R) engine; and California emissions (RPO YF5). This Special Policy covers all vehicles within these model years, with these engine and emissions RPO's. PARTS INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4781 Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering parts. Normal orders should be placed on a DRO Daily Replenishment Order. In an emergency, parts should be ordered on a CSO = Customer Special Order. IMPORTANT: Isuzu Parts Ordering: In order to comply with the 10-digit Isuzu part numbering system, Isuzu dealers must add an "8" to the beginning and a "0" to the end of the listed 8-digit part numbers when ordering parts through AIPDN. CUSTOMER NOTIFICATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4782 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4783 Customers will be notified of this special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). SERVICE PROCEDURE System Check: Use strategy-based diagnoses listed in the front of the Driveability and Emissions section of the service manual. If the SCPI system is operating properly, inform the customer that the vehicle does not have the condition listed in the owner letter. If poor driveability conditions persist, inform the customer that any further diagnosis and repairs will be at their expense if the vehicle is outside the parameters of the new vehicle warranty. SCPI Injector Cleaning Procedure: If diagnosis leads to sticking poppet nozzles, use the service procedure from Service Bulletin 00-06-04-003B to clean the SCPI poppet nozzles. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. If the poppet nozzles have previously been cleaned and the sticking condition has reoccurred, refer to the correction paragraph below. SCPI Fuel Tank Fill Pipe Assembly for 1997-99 M/L Van and 1999 - some 2000 C/K Truck: with 4.3L, 5.0L, 5.7L engines and built prior to listed VIN/Production dates on Service Bulletin 00-06-04-018: If diagnosis leads to sticking poppet nozzles on these models, use the service procedure from Service Bulletin 00-06-04-018 to replace the fuel tank fill pipe assembly, if this procedure has not been performed previously. Previous service procedure can be verified by checking GMVIS for Labor Operation L1065 on "M/L" trucks with replacement part number 15050573; or Labor Operation L1065 on "C/K" trucks with replacement part numbers 15747585 or 15747588. Correction: If, after cleaning the SCPI poppet nozzles, the normal service manual diagnosis still indicates that the SCPI is the cause of the customer complaint, or if the injectors have previously been cleaned and the vehicle has again experienced sticking poppet nozzles, refer to Service Bulletin 00-06-04-003B and replace the SCPI fuel assembly with the MFI fuel assembly. Please note that the service bulletin term for SCPI is Central Sequential Fuel Injection (CSFI), but is referring to the same fuel system assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 99066F > Mar > 03 > Campaign - Fuel Injector Sticking Closed > Page 4784 CLAIM INFORMATION For vehicles repaired under this special policy, submit a claim with the information indicated. CUSTOMER REIMBURSEMENT Customer requests for reimbursement are for any previously paid repairs to, or replacement of, the Sequential Central Port Fuel Injection (SCPI) system. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service, or 200,000 miles, whichever occurs first. The requests are to be submitted within two (2) years of the date on which the repair was paid or within two (2) years of the date of this Special Policy Bulletin, whichever is greater. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. Customers from the State of California, must submit requests for reimbursement directly to (Divisions) per instructions in the owner letter. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications Fuel Level Specifications The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 4788 Fuel Pump And Sender Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 4789 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 4790 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Pump And Sender Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4794 Fuel Tank Unit: Description and Operation FUEL SENDER ASSEMBLY Fuel Sender Assembly The fuel sender assembly consists of the following major components: ^ The fuel level sensor (6) ^ The Fuel Tank Pressure (FTP) sensor (1) ^ The fuel pump module (2) ^ The fuel strainer (3) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4795 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39765 Fuel Sender Locknut Wrench REMOVAL PROCEDURE 1. Remove the fuel tank. NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 2. Disconnect the fuel sender electrical connectors. 3. Disconnect the fuel and EVAP pipes from the fuel sender. 4. Remove the fuel sender assembly retaining ring using the J 39765. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container. 5. Remove the fuel sender assembly and the seal. Discard the seal. 6. Clean the fuel sender sealing surfaces. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Install the new seal on the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4796 IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm. 2. Install the fuel sender assembly into the fuel tank. 3. Install the fuel sender assembly retaining ring using the J 39765. 4. Connect the fuel and EVAP pipes to the fuel sender. 5. Connect the fuel sender electrical connectors. 6. Install the fuel tank. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4800 Idle Air Control (IAC) Valve Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4801 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The valve consists of a movable pintle, driven by a gear attached to a two phase bi-polar permanent magnet electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has two separate windings that are called coils. Each coil is fed by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) may set. DIAGNOSTIC AIDS Inspect for the following conditions: ^ A skewed high throttle position (TP) sensor ^ Restricted air intake system ^ Objects blocking the IAC passage or throttle bore ^ The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve ^ Proper operation and installation of all air intake components ^ Proper installation and operation of the mass air flow (MAF) sensor, if equipped ^ A tampered with or damaged throttle stop screw ^ A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped ^ Excessive deposits in the IAC passage or on the IAC pintle ^ Excessive deposits in the throttle bore or on the throttle plate ^ Vacuum leaks ^ Excessive load on engine i.e. transmission, power steering, alternator, etc. ^ A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms-Computers and Controls Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures ^ A low or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms-Computers and Controls Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures ^ If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4802 Steps 1-6 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4803 Steps 7-11 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4804 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC counts are incrementing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4805 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Disconnect the harness connector from the idle air control (IAC) valve. 4. Remove the IAC valve attaching fasteners. NOTE: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle. The force required to move the pintle may damage the threads on the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result. 5. Remove the IAC valve assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4806 6. Remove the O-ring. CLEANING AND INSPECTION PROCEDURE 1. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage. ^ Use a carburetor cleaner and a parts cleaning brush in order to remove any carbon deposits. Follow the instructions on the container. ^ Do not use a cleaner that contains methyl ethyl ketone. MEK is an extremely strong solvent and not necessary for this type of deposit ^ Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft. ^ If the air passage has heavy deposits, remove the throttle body for a complete cleaning. 2. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if damaged. INSTALLATION PROCEDURE IMPORTANT: If you are installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. 1. Measure the distance between tip of the IAC valve pintle and the mounting flange. If the distance is more than 28 mm (1.10 in), use finger pressure in order to slowly retract the pintle. The force required to retract the pintle of a new valve will not cause damage to the valve. 2. Lubricate the IAC valve O-ring with clean engine oil. 3. Install the IAC valve assembly. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4807 4. Install the attaching fasteners. Tighten Tighten the IAC valve fasteners to 3 N.m (27 lb in). 5. Connect the IAC harness connector. 6. Install the engine cover. 7. Reset the IAC valve pintle position. IAC VALVE RESET PROCEDURE 1. Turn ON the ignition for 5 seconds, leaving the engine OFF. 2. Turn OFF the ignition for 10 seconds. 3. Start the engine. 4. Check for the proper idle speed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 Fuel Pump Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair AIR CLEANER OUTLET RESONATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the air cleaner outlet retaining nut (1). 4. Remove the air cleaner outlet duct (2) from the throttle body assembly. 5. Loosen the air cleaner outlet duct from the MAF/IAT sensor. 6. Remove the air cleaner outlet duct. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the air cleaner outlet duct to the MAF/IAT sensor. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair > Page 4848 Tighten the clamp to 4 N.m (35 lb in). 2. Install the air cleaner outlet duct (2) on the throttle body assembly. 3. Tighten the retaining nut (1). Tighten Tighten the nut 2 N.m (18 lb in). 4. Install the engine cover. 5. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 Air Flow Meter/Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Mass Air Flow (MAF) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4887 Air Flow Meter/Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4888 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Release the air cleaner cover retainer clips. NOTE: ^ Handle the MAF sensor carefully. ^ Do not drop the MAF sensor in order to prevent damage to the MAF sensor. ^ Do not damage the screen located on the air inlet end of the MAF. ^ Do not touch the sensing elements. ^ Do not allow solvents and lubricants to come in contact with the sensing elements. ^ Use a small amount of a soap based solution in order to aid in the installation. 4. Remove the air cleaner outlet duct from the MAF sensor by loosening the hose clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4889 5. Disconnect the air cleaner cover from the front of the MAF sensor by loosening the hose clamp. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Point the flow arrows on the MAF sensor away from the air cleaner. 1. Attach the MAF sensor to the air cleaner cover by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). 2. Attach the air cleaner outlet duct to the MAF sensor by tightening the hose clamp. Tighten Tighten the clamp to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Diagrams > Page 4890 3. Install the air cleaner cover by fastening the air cleaner cover retainer clips. 4. Connect the MAF sensor harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4928 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4929 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4930 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Remove the air cleaner outlet resonator. 4. Remove the air cleaner outlet resonator adapter stud. 5. Remove the cruise control cable. 6. Remove the accelerator cable. 7. Remove the stud and nuts retaining the accelerator control cable bracket and position bracket aside. 8. Disconnect the (IAC) valve harness connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 4935 9. Disconnect the (TP) sensor harness connector. 10. Remove the throttle body retaining studs. 11. Remove the throttle body assembly. 12. Discard the throttle body seal. INSTALLATION PROCEDURE CAUTION: Refer to Safety Glasses Caution in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 4936 1. Clean the gasket surface on the intake manifold. 2. Install the throttle body assembly with a new seal. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the throttle body assembly retaining studs. Tighten Tighten the studs to 9 N.m (80 lb in). 4. Install the air cleaner outlet resonator adapter stud. Tighten Tighten the studs to 8 N.m (71 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 4937 5. Connect the TP sensor harness connector. 6. Connect the IAC valve harness connector. 7. Install the accelerator control cable bracket using the fasteners. Tighten Tighten the fasteners to 12 N.m (106 lb in). IMPORTANT: Ensure the accelerator and the cruise control cables do not hold the throttle open. 8. Install the accelerator cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 4938 9. Install the cruise control cable. 10. Install the air cleaner outlet resonator. 11. Install the engine cover. 12. Connect the negative battery cable. IMPORTANT: The accelerator pedal should operate freely without binding between full and closed throttle. 13. Use the following procedure in order to check the accelerator pedal operation. 13.1. Depress the pedal to the floor. 13.2. Release the accelerator pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 4939 Throttle Body: Service and Repair Throttle Body Cleaning Procedure 1. Remove the air cleaner outlet duct. 2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. NOTE: Do not subject a throttle body assembly which contains the following components to an immersion cleaner or a strong solvent: ^ Throttle position (TP) sensor ^ Idle air control (IAC) valve ^ Sealed throttle shaft bearings The cleaners will damaged the electric components or sensors. The cleaners will damage some of these components that contain seals or O-rings. Solvents can wash away or break down the grease used on non-serviceable throttle shaft bearings. Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools may damage the throttle body components. Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or an equivalent product. 4. If the deposits are excessive, remove and disassemble the throttle body for cleaning. 5. After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent. 6. If you removed and disassembled the throttle body for cleaning, assemble and install the throttle body. 7. Install the air cleaner outlet duct. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair ACCELERATOR CONTROLS CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the engine cover. 2. Remove the air cleaner outlet duct. 3. Remove the accelerator cable from the throttle lever. 4. Remove the accelerator cable from the engine cable bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 4943 5. Remove the accelerator cable (1) from the accelerator pedal (3). 6. Remove the accelerator cable assembly from the bulkhead (1). INSTALLATION PROCEDURE 1. Install the accelerator cable to the bulkhead (1). ^ Ensure all locking tabs (3) are expanded to secure cable assembly to dash panel (1). ^ Ensure dash panel insulator does not come in contact with any portion of the cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 4944 2. Install the accelerator cable (1) to the accelerator pedal (3). Ensure the retainer (2) is securely seated to the accelerator pedal. 3. Install the accelerator cable to the engine cable bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 4945 4. Install the accelerator cable to the throttle lever. 5. Install the air cleaner outlet duct. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4954 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Throttle Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Throttle Position (TP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4983 Throttle Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4984 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the throttle position (TP) sensor harness connector. 3. Remove the mounting bolts from the TP sensor. NOTE: The TP sensor is an electrical component. Do not soak the TP sensor in any liquid cleaner or solvent, as damage may result. 4. Remove the TP sensor and gasket from the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 4985 1. With the throttle valve closed, install the TP sensor on the throttle shaft. Rotate the TP sensor counterclockwise in order to align the mounting holes. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the TP sensor mounting bolts. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector. 4. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5024 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5025 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5026 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5027 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5028 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5029 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5030 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5031 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5032 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 5041 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 5047 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5048 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5083 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5084 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5087 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5088 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5089 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5090 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5091 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: Customer Interest Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 5100 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 5101 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 Distributor: All Technical Service Bulletins Ignition System - SES Lamp ON/Misfire/DTC P0300 Bulletin No.: 03-06-04-041A Date: January 28, 2005 TECHNICAL Subject: Poor Engine Performance - Misfire, Rough Idle, Stalls, Engine Cranks but Does Not Run, Service Engine Soon/Check Engine Light Illuminated, DTC P0300 Set (Inspect Distributor Ignition (DI) System Components and Replace As Necessary) Models: 2001-2003 Chevrolet Astro, Blazer, Express, S-10 2001-2003 GMC Jimmy, Safari, Savana, Sonoma 2001 Oldsmobile Bravada with 4.3L, 5.0L or 5.7L Gas Engine (VINs W, X, M, R - RPOs L35, LU3, L30, L31) Supercede: This bulletin is being revised to delete a model and add information to subject and inspection of distributor vent screens. Please discard Corporate Bulletin Number 03-06-04-041 (Section 06 Engine/Propulsion System). Condition Some customers may comment on poor engine performance and the Service Engine Soon/Check Engine light being illuminated. Upon investigation, the technician may find DTC P0300 set. Cause This condition may be due to high levels of internal corrosion in the distributor, causing misfire, rough idle, stall and Engine Cranks But Does Not Run. This corrosion is attributed to a lack of airflow internal to the cap caused by the vent screens being clogged with debris. Correction Remove the vent screens and inspect the internal components of the Distributor Ignition System using the procedure listed below. If the distributor base has to be replaced, the vent screens will also have to be removed on the new distributor. If there is evidence of this internal corrosion, replace the affected component. Refer to the appropriate procedure in the Engine Controls sub-section of the applicable Service Manual. Important: All of these inspections can be done on-vehicle. 1. Inspect the distributor cap. You may notice a white residue on the cap walls. For higher mileage occurrences, the interior of the cap may have changed to medium brown in color 2. Inspect the distributor rotor. You may notice the presence of black streaks on the plastic surface. More typical evidence would be visible green spots on the copper surface of the rotor segment. 3. Inspect the distributor base. You may notice high levels of surface rust on the distributor shaft or surface contamination on the sensor hold down screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 5107 4. Inspect the distributor vent screens (1). If the vent screens are present, remove them by using a plastic-handled, long blade awl or pick (2). Insert into the airflow vent screens and pop them out. Refer to the figure for removal procedure. If the vent screens have been removed from the base of the distributor, then check the airflow inlets for being clogged with debris. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Distributor: > 03-06-04-041A > Jan > 05 > Ignition System - SES Lamp ON/Misfire/DTC P0300 > Page 5108 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul Distributor: Service and Repair Distributor Overhaul DISASSEMBLY PROCEDURE 1. Remove the engine cover. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 2. Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (2). 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). If not, replace the distributor. 4. Remove the 2 screws from the rotor. 5. Remove the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5111 6. Note the locating holes that the rotor was removed from: ^ The rotor screw holes (1) ^ The rotor locator pin holes (2) 7. Line up the square-cut hole in the vane wheel with the CMP sensor. 8. Remove the 2 screws that hold the camshaft position (CMP) sensor. 9. Discard the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5112 10. Remove the CMP sensor. 11. Note the dimple located below the roll pin hole on one side of the gear. The dimple will be used to properly orient the gear onto the shaft during reassembly. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 12. Support the distributor drive gear in a V-block or similar fixture. 13. Drive out the roll pin with a suitable punch. 14. Remove the driven gear from the distributor shaft. 15. Remove the round washer. 16. Remove the tang washer. 17. Remove the shim washer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5113 18. Remove the old oil seal. ASSEMBLY PROCEDURE IMPORTANT: Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 1. Line up the square-cut hole in the vane wheel for the camshaft position (CMP) sensor. 2. Insert the sensor into the housing. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5114 3. Install two new screws for the camshaft position (CMP) sensor. Tighten Tighten the screws to 2.2 N.m (19 lb in). 4. Identity the correct rotor mounting position: ^ At the rotor screw holes (1) ^ At the rotor locator pin holes (2) 5. Install the distributor rotor according to the index marks. 6. Install two rotor hold down screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5115 7. Install the shim washer (1) on the bottom of the distributor shaft. 8. Install the tang washer. 9. Install the round washer. 10. Install the driven gear according to the index marks. 11. Align the rotor segment as shown for a V6 engine (1) or V8 engine (2). 12. Install the gear and align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3). 13. Check to see if the driven gear is installed incorrectly. On an incorrectly installed driven gear, the dimple will be approximately 180 degrees opposite the rotor segment when the gear is installed in the distributor. CAUTION: Refer to Safety Glasses Caution in Service Precautions. 14. Support the distributor drive gear in a V-block or similar fixture. 15. Install the roll pin with a suitable punch and hammer in order to hold the driven gear in the correct position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5116 16. Install the new oil seal under the mounting flange of the distributor base. 17. Install the distributor. 18. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5117 Distributor: Service and Repair Distributor Replacement REMOVAL PROCEDURE NOTE: There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: ^ The intake manifold ^ The cylinder head ^ The camshaft ^ The timing chain or sprockets ^ The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor. 1. Turn OFF the ignition. 2. Remove the engine cover. 3. Remove air cleaner assembly. 4. Remove the air intake resonator assembly. 5. Remove the spark plug wires from the distributor cap. ^ Twist each spark plug 1/2 turn. ^ Pull only on the wire boot in order to remove the wire from the distributor cap. 6. Remove the electrical connector from the base of the distributor. 7. Remove the 2 screws that retain the distributor cap to the housing. 8. Discard the screws. 9. Remove the distributor cap from the housing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5118 10. Use a grease pencil in order to mark the position of the rotor in relation to the distributor housing (1). 11. Mark the distributor housing and the intake manifold with the grease pencil. 12. As the distributor is being removed from the engine, watch the rotor move in a counter-clockwise direction about 42 degrees. This will appear as slightly more than one clock position. 13. Note the position of the rotor segment. 14. Place a second mark on the base of the distributor (2). This will aid in achieving the proper rotor alignment during the distributor installation. 15. Remove the mounting clamp hold-down bolt. 16. Remove the distributor. INSTALLATION PROCEDURE 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5119 1. If installing a new distributor assembly, place 2 marks on the new distributor housing in the same location as the marks on the original housing. 2. Remove the new distributor cap, if necessary. 3. Align the rotor with the second mark (2). 4. Guide the distributor into the engine. 5. Align the hole in the distributor hold-down base over the mounting hole in the intake manifold. 6. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees. 7. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1). ^ If the rotor segment is not aligned with the mark, the driven gear teeth and the camshaft have meshed one or more teeth out of alignment. ^ In order to correct this condition, remove and reinstall the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5120 NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). 9. Install the distributor cap. 10. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 11. Install the electrical connector to the distributor. 12. Install the spark plug wires to the distributor cap. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5121 13. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 14. Refer to Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 15. Install the engine cover. INSTALLATION PROCEDURE 2 IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks spaced 90 degrees apart which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3). 1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5122 2. Align the white paint mark on the bottom stem of the distributor and the pre-drilled indent hole in the bottom of the gear (3). NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly: ^ The distributor driven gear ^ The distributor shaft ^ The rotor holes Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result. 3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1). ^ The alignment will not be exact. ^ If the driven gear is installed incorrectly, the dimple Will be approximately 180 degrees opposite of the rotor segment when installed in the distributor. 4. Use a long screw driver in order to align the oil pump drive shaft to the drive tab of the distributor. 5. Guide the distributor into the engine. Ensure the flat portion of the distributor housing is facing toward the front of the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5123 6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. If the rotor segment does not come within a few degrees of the pointer, repeat the procedure in order to achieve the proper alignment. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the distributor mounting clamp bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5124 8. Install the distributor cap. 9. Install the new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). 10. Install the electrical connector to the distributor. 11. Install the spark plug wires to the distributor cap. 12. Install the ignition coil wire. Note the correct orientation of the wire boot. IMPORTANT: If the malfunction indicator lamp illuminates after installing the distributor and DTC P1345 is set, the distributor has been installed incorrectly. 13. Repeat Installation Procedure 2 if the malfunction indicator lamp illuminates after installing the distributor. 14. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Service and Repair > Distributor Overhaul > Page 5125 Distributor: Service and Repair Distributor Inspection 1. Remove the engine cover. IMPORTANT: Discoloration of the cap and some whitish build up around the cap terminals is normal. Yellowing of the rotor cap, darkening and some carbon build up under the rotor segment is normal. Replacement of the cap and the rotor is not necessary unless there is a driveability concern. 2. Inspect the cap for cracks, tiny holes or carbon tracks between the cap terminal traces. Diagnose the carbon tracks using the following procedure: 2.1. Remove the cap. 2.2. Place 1 lead from the DMM on a cap terminal. 2.3. Use the other lead in order to probe all other terminals and the center carbon ball. 2.4. Move the base lead to the next terminal. Probe all other leads. 2.5. Continue this procedure until you test all the secondary terminals. 2.6. If there are any non-infinite readings, replace the cap. 3. Inspect the cap for excess build-up of corrosion on the terminals. Scrape clean the terminals. Replace the cap if the corrosion is excessive. Some buildup is normal. 4. Inspect the rotor segment for excess wear. Replace the rotor if excess looseness in the rotor segment is present. 5. Inspect the shaft for shaft-to-bushing looseness: 5.1. Inspect the housing for cracks or damage. 5.2. Insert the shaft in the housing. 5.3. If the shaft wobbles, replace the housing assembly. 6. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection Ignition Cable: Service and Repair Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires - Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: ^ Tearing ^ Piercing ^ Arcing ^ Carbon tracking ^ Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 5130 Ignition Cable: Service and Repair Spark Plug Wire Replacement REMOVAL PROCEDURE 1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Spark Plug Wire Inspection > Page 5131 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations Ignition Coil: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 5135 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 5136 Ignition Coil Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 5137 Ignition Coil: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS The ICM is connected to the PCM by an Ignition Control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 5138 Ignition Coil: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connectors. 3. Remove the ignition coil wire to the distributor. 4. Remove the studs holding the bracket and the ignition coil to the intake manifold. 5. Remove the bracket and the ignition coil. 6. Drill and punch out the two rivets holding the ignition coil to the bracket. 7. Remove the ignition coil from the bracket. INSTALLATION PROCEDURE IMPORTANT: A replacement ignition coil kit comes with 2 screws in order to attach the ignition coil to the bracket. 1. Install the ignition coil to the bracket with the 2 screws. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ignition coil and the bracket to the intake manifold with studs. Tighten Tighten the studs to 11 N.m (97 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 5139 3. Install the ignition coil wire. The wire must not touch anything like the dip stick. Rubbing will make a ground or short after time of use. 4. Install the electrical connectors. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 5144 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5145 Ignition Control Module (ICM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5146 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS The ICM is connected to the PCM by an Ignition Control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5147 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5185 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5186 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 5187 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Component Locations > Page 5193 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 5194 Ignition Control Module (ICM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 5195 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS The ICM is connected to the PCM by an Ignition Control (IC) circuit. The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil. The coil driver in the ICM controls current through the ignition coil based on signal pulses from the PCM. There is no back-up or by-pass function in the ICM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 5196 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the electrical connector (3). 3. Remove the screws (4) holding the ignition control module (2) and the heat sink (1) to the bracket. 4. Remove the ignition control module and the heat sink. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the ignition control module (2) and the heat sink (1) on the bracket with the screws (4). Tighten Tighten the screws to 3.5 N.m (31 lb in). 2. Reconnect the electrical connectors (3). 3. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Camshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5226 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Camshaft Position (CMP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5235 Camshaft Position Sensor: Description and Operation The CMP sensor is a hall-effect sensor located in the ignition distributor base, and uses the same type of circuits as the CKP sensor. The CMP sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor information is used by the PCM to determine the position of the valve train relative to the CKP. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5236 Camshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5237 Camshaft Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the engine cover. 2. Disconnect the spark plug wires and ignition coil wire from the distributor. 3. Disconnect the camshaft position (CMP) sensor harness connector from the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5238 4. Remove the distributor cap screws. 5. Remove the distributor cap. 6. Remove the rotor screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5239 7. Remove the rotor. 8. Align the square slot in the reluctor wheel with the CMP sensor. 9. Remove the CMP screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5240 10. Remove the CMP sensor. INSTALLATION PROCEDURE IMPORTANT: Do not use the old cap, CMP sensor, and rotor screws. Use the replacement screws that have been coated with a thread locking compound. 1. Insert the CMP sensor through the reluctor wheel slot. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install new CMP mounting screws. Tighten Tighten the bolts to 2.2 N.m (19 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5241 3. Install the rotor onto the reluctor wheel. 4. Install new rotor screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5242 5. Install the distributor cap. 6. Install new distributor cap screws. Tighten Tighten the screws to 2.4 N.m (21 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5243 7. Connect the CMP sensor harness connector. 8. Connect the spark plug wires and ignition coil wire. 9. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: Customer Interest Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 5252 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set Crankshaft Position Sensor: All Technical Service Bulletins Engine Controls - Engine Runs Rough/MIL ON/DTC's Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 02-06-04-059 Date: December, 2002 TECHNICAL Subject: Engine Runs Rough, Service Engine Soon Light On, DTC's P0300 or P0335 Set (Shim Crankshaft Sensor) Models: 2002-03 Chevrolet Astro, Blazer, Express, Silverado and S-10 Truck Models 2002-03 GMC Jimmy, Safari, Savana, Sierra and Sonoma Truck Models with 4.3L V-6 Engine (VINs W, X RPOs L35, LU3) Condition Some owners may comment on a rough running condition or a Service Engine Soon (SES) light being illuminated. Upon investigation, the technician may find a DTC code P0300 or P0335. Cause The crankshaft sensor may be contacting the reluctor wheel. Correction Remove the crankshaft sensor. Refer to the Crankshaft Position Sensor Replacement procedure in the Engine Controls-4.3L sub-section of the Service Manual. After removing the sensor, inspect the end of it for witness marks that would indicate contact with the crankshaft. If contact with the reluctor ring is indicated, then inspect the front cover for cracking or other signs of alignment concerns. If the inspection indicates that the cover is causing mis-alignments, replace the cover. If replacing the cover, then the 0.5 mm shim is not needed. If the inspection of the front cover indicates that the cover is not the cause of mis-alignments, then the sensor should be shimmed. Add one shim between the sensor and the front cover. If the concern still exists, then add the second shim. Unless the sensor has been rubbed through the casing or deformed by contact with the crankshaft, it should not be replaced. In either case, the crankshaft relearn procedure should be performed after any repairs. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Position Sensor: > 02-06-04-059 > Dec > 02 > Engine Controls - Engine Runs Rough/MIL ON/DTC's Set > Page 5258 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5259 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 Crankshaft Position Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Crankshaft Position (CKP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5294 Crankshaft Position Sensor: Description and Operation The CKP sensor is a three wire sensor based on the magneto resistive principle. A magneto resistive sensor uses two magnetic pickups between a permanent magnet. As an element such as a reluctor wheel passes the magnets the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse. The PCM supplies a 12-volt, low reference, and signal circuit to the CKP sensor. The sensor returns a digital ON/OFF pulse 3 times per crankshaft revolution for the V6 engine, 4 times for the V8 engine. The CKP sensor reads the crankshaft mounted reluctor wheel to identify pairs of cylinders at top dead center (TDC). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 5295 Crankshaft Position Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure IMPORTANT: For additional diagnostic information, refer to DTC P1336. 1. Install a scan tool. 2. With a scan tool, monitor the powertrain control module (PCM) for diagnostic trouble codes (DTCs). If other DTCs are set, except DTC P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. With a scan tool, select the crankshaft position (CKP) variation learn procedure. 4. Observe the fuel cut-OFF for the engine that you are performing the learn procedure on. 5. The scan tool instructs you to perform the following: ^ Block the drive wheels. ^ Apply the vehicles parking brake. ^ Cycle the ignition from OFF to ON. ^ Apply and hold the brake pedal. ^ Start and idle the engine. ^ Turn OFF the A/C. ^ Place the vehicles transmission in Park (A/T) or Neutral (M/T). ^ The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTCs that set. - Camshaft position (CMP) sensor activity - If there is a CMP sensor condition, refer to the applicable DTCs that set. - Engine coolant temperature (ECT) - If the ECT is not warm enough, idle the engine until the ECT reaches the correct temperature. 6. With the scan tool, enable the CKP system variation learn procedure. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position (TP) after the learn procedure is complete. 7. Slowly increase the engine speed to the RPM that you observed. 8. Immediately release the throttle when fuel cut-OFF is reached. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message and no additional DTCs set, refer to Symptoms - Engine. If a DTC set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5298 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE IMPORTANT: The CKP System Variation Learn Procedure will need to be performed whenever the crankshaft position (CKP) sensor is removed or replaced. Refer to CKP System Variation Learn Procedure. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If the vehicle is equipped with the underbody shield package, then remove the steering linkage shield mounting bolts. 3. Remove the steering linkage shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5299 4. Disconnect the CKP sensor harness connector. 5. Remove the CKP sensor mounting bolt. 6. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5300 IMPORTANT: ^ When installing the CKP sensor, make sure the sensor is fully seated before tightening the mounting bolt. A poorly seated CKP sensor may perform erratically and may set false DTCs. ^ Do not reuse the original O-ring. 1. Replace the CKP sensor O-ring. 2. Lubricate the O-ring with clean engine oil before installing the CKP sensor. IMPORTANT: Make sure the CKP sensor mounting surface is clear and free of burrs. 3. Install the CKP sensor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the CKP sensor mounting bolt. Tighten Tighten the CKP sensor mounting bolt to 9 N.m (80 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5301 5. Connect the CKP sensor harness connector. 6. Install the steering linkage shield. 7. Install the steering linkage shield mounting bolts. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 5302 Tighten the bolts to 33 N.m (24 lb ft). 8. Lower the Vehicle. 9. Perform the CKP System Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Knock Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 Knock Sensor (KS) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5345 Knock Sensor: Description and Operation PURPOSE The Knock Sensor (KS) system enables the Powertrain Control Module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: ^ The broadband single wire sensor ^ The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: ^ All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. ^ The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near Top Dead Center (TDC) of the firing stroke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5346 Knock Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Computers and Control Systems Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5347 Knock Sensor: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the knock sensor harness connector (3). 4. Remove the knock sensor bolt (1) and knock sensor (2). INSTALLATION PROCEDURE NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 1. Install the knock sensor (2) and the knock sensor bolt (1). Tighten Tighten the sender to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector (3). 3. Install the engine cover. 4. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Ignition System Specifications Ignition System Specifications Spark Plug Torque 15 N.m Spark Plug Gap 1.52 mm Spark Plug Type R41-932 [AC plug type] Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5351 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................ R41-932 (AC plug type) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection Spark Plug: Service and Repair Spark Plug Inspection SPARK PLUG USAGE 1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: ^ Spark plug fouling - Colder plug ^ Pre-ignition causing spark plug and/or engine damage - Hotter plug SPARK PLUG INSPECTION 1. Inspect the terminal post (1) for damage. ^ Inspect for a bent or broken terminal post (1). ^ Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: ^ Inspect the spark plug boot for damage. ^ Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5354 3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). 4. Inspect for evidence of improper arcing. ^ Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. ^ Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. ^ Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). ^ Inspect for a broken or worn side electrode (3). ^ Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. ^ Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. ^ Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. ^ Inspect for excessive fouling. 5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION 1. Normal operation - Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon Fouled - Dry, fluffy black carbon, or soot caused by the following conditions: ^ Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion ^ Reduced ignition system voltage output Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5355 - Weak coils - Worn ignition wires - Incorrect spark plug gap ^ Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit Fouling - Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug Inspection > Page 5356 Spark Plug: Service and Repair Spark Plug Replacement REMOVAL PROCEDURE 1. Remove the spark plug wires. 2. Loosen each spark plug 1 or 2 turns. 3. Brush or air blast away any dirt from around the spark plugs. 4. Remove the spark plugs 1 at a time. Place each plug in a tray marked with the corresponding cylinder numbers. INSTALLATION PROCEDURE 1. Properly position each spark plug washer. 2. Inspect each spark plug gap. Adjust each plug as needed Specification Spark plug gap: 1.524 mm (0.060 in). NOTE: Refer to Fastener Notice in Service Precautions. 3. Hand start the spark plugs in the corresponding cylinders. 4. Tighten the spark plugs. Tighten ^ For used heads tighten the spark plugs to 15 N.m (11 lb ft). ^ For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft). ^ For new iron heads tighten the spark plugs to 30 N.m (22 lb ft). 5. Install the spark plug wires. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5363 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator from the steering column jacket assembly. 6. Remove the automatic transmission shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the lower steering column trim cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5367 6. Enable the SIR system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5371 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5372 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5373 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Fastener Tightening Specifications TCC Solenoid Assembly to Case Bolt ................................................................................................................................ 8.0 - 14.0 Nm (6 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5377 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5378 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5379 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5380 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5381 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 5387 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5391 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5392 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5393 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5394 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5395 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5399 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5400 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > PCM/BCM Replacement - DTC's B001/B1271/B1780 Set PROM - Programmable Read Only Memory: Technical Service Bulletins PCM/BCM Replacement DTC's B001/B1271/B1780 Set File In Section: 06 - Engine/Propulsion System Bulletin No.: 99-06-03-010A Date: June, 2001 INFORMATION Subject: DTCs B1001, B1271 or B1780 Set When Replacing/Reprogramming Other Modules Models: 1999-2002 All Passenger Cars and Trucks With Class 2 Serial Data Communication Between Modules This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-06-03-010 (Section 06 - Engine/propulsion System). Class 2 Serial Data Communication allows control modules (i.e. the Powertrain Control Module (PCM), the Body Control Module (BCM), the Dash Integration Module (DIM), the Instrument Panel Cluster (IPC), the radio, the Heating, Ventilation and Air Conditioning (HVAC) Controller, and the Sensing and Diagnostic Module (SDM) to exchange information. This information may be operational information or identification information. Among the identification information exchanged and compared within these modules is the Vehicle Identification Number (VIN). Typically, the PCM broadcasts a portion of the VIN, while another module broadcasts another portion of the VIN. This information is compared by the SDM in order to ensure installation is in the correct vehicle. When the broadcast VIN does not match the VIN stored within the SDM, the following actions occur: ^ DTC B1001 Option Configuration Error is set and deployment of the airbags is inhibited. ^ The VIN information is also used by the radio in order to prevent theft. When the broadcast VIN does not match the VIN stored within the radio, a DTC B1271 ora DTC B1780 Theft Locked is set and the radio is inoperative. This situation may occur when a vehicle is being repaired. When a PCM or a body control type module is replaced, the VIN information must be programmed into the replaced (new) control module. A module which has had VIN information entered into it (for example, one taken from another vehicle) cannot be reprogrammed. VIN information can only be entered into new modules. The ignition must be ON in order to program the control module. Since the VIN information is broadcast when the ignition goes to ON from any other ignition switch position, DTCs may be set in the SDM and/or the radio. Therefore, always follow the specified control module replacement procedures. 1. After completing the repair, turn OFF the ignition for at least 30 seconds. 2. Turn ON the ignition and check for DTCs using a scan tool. If DTCs B1001, B1271, or B178C are present with a history status, DO NOT REPLACE THE SDM OR THE RADIO. 3. Clear the DTCs from all modules using the scan tool. The SDM and/or the radio should then operate properly. 4. Ensure the proper operation of the SDM by turning OFF the ignition and then turning ON the ignition. The air bag warning indicator should flash seven times and then go OFF. Refer to Corporate Bulletin Number 99-09-41-001 for additional information regarding proper reprogramming of the new/replaced module. Clearing codes from the other modules is part of the replacement and reprogramming procedure for the replaced module. The repair is not complete unless all codes have been cleared from all modules. DO NOT SUBMIT CLAIMS FOR OTHER MODULE REPLACEMENTS OR REPROGRAMMING. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5414 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator from the steering column jacket assembly. 6. Remove the automatic transmission shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the lower steering column trim cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5418 6. Enable the SIR system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5422 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5423 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5424 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Fastener Tightening Specifications TCC Solenoid Assembly to Case Bolt ................................................................................................................................ 8.0 - 14.0 Nm (6 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5428 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5429 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5430 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5431 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5432 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5438 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator from the steering column jacket assembly. 6. Remove the automatic transmission shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the lower steering column trim cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5442 6. Enable the SIR system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5446 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5447 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5448 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Fastener Tightening Specifications TCC Solenoid Assembly to Case Bolt ................................................................................................................................ 8.0 - 14.0 Nm (6 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5452 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5453 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5454 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5455 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5456 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Accumulator: Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5461 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5462 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5463 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5464 Accumulator: Specifications Fastener Tightening Specifications Forward Accumulator Cover to Valve Body Bolt ............................................................................................................... 8.0 - 14.0 Nm (6 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5465 Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets ^ Tools Required J 25025-B Pump and Valve Body Alignment Pin Set - J 36850 Transjel Lubricant Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. Important: The 1-2 accumulator can be removed without removing the control valve assembly. 3. Remove the control valve body. 4. Remove the accumulator cover retaining bolts. 5. Remove the 1-2 accumulator cover assembly. 6. Disassemble the 1-2 accumulator. 6.1. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. 6.2. Remove the 1-2 accumulator inner and outer springs. 7. Inspect the 1-2 accumulator inner and outer springs for cracks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5466 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches 11. Remove the spacer plate support retaining bolts. Important: Use care not to drop the following items that will be removed along with the spacer plate: ^ The number 1 checkball ^ The 3-4 accumulator spring Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5467 ^ The 3-4 accumulator pin 12. Remove the spacer plate support. 13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 14. Remove the 3-4 accumulator piston (2). 15. Inspect the 3-4 accumulator spring for cracks. 16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 17. Inspect the 3-4 accumulator piston for the following defects: ^ Porosity ^ Cracks ^ Scoring ^ Nicks and scratches Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5468 Installation Procedure 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5469 4. Install the J 25025-B (2, 3) to the transmission case. 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. ^ The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. ^ The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 10. Install the spacer plate support and the spacer plate support retaining bolts. Tighten the spacer plate support retaining bolts to 11 Nm (97 inch lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5470 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. 13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. 14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5471 15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. Tighten the accumulator cover retaining bolts to 11 Nm (97 inch lbs.). 16. Remove the J 25025-B from the transmission case. 17. Install the control valve body. 18. Install the transmission oil pan and filter. 19. Lower the vehicle. 20. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 5480 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 5486 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 5487 Band Apply Servo: Service and Repair 2-4 Servo ^ Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission heat shield. 3. Place a drain pan under the vehicle. 4. Remove the oil pan bolt below and to the left of the 2-4 servo cover. 5. Install the J 29714-A to the oil pan rail. 6. Tighten the bolt on the J 29714-A in order to compress the servo cover. 7. Remove the servo cover retaining ring. 8. Loosen the bolt on the J 29714-A to release tension on the servo cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 5488 9. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 10. Remove the 2-4 servo assembly from the transmission. 11. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston, and the piston inner housing for the following defects: ^ Cracks ^ Scoring ^ Burrs and nicks Installation Procedure 1. Install the new seals on the pistons and the servo cover. 2. Lubricate the seals with clean transmission fluid. 3. Install the 2-4 servo assembly into the 2-4 servo bore. 4. Install the servo cover and O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 5489 5. Install the J 29714-A. 6. Tighten the bolt on the J 29714-A in order to compress the servo cover. 7. Install the servo cover retaining ring. 8. Remove the J 29714-A from the oil pan flange. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the oil pan bolt. Tighten the oil pan bolt to 11 Nm (97 inch lbs.). 10. Install the transmission heat shield. 11. Remove the drain pan. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis Case: Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5494 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5495 Case: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5496 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5497 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5498 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - Cracked Case Diagnosis > Page 5499 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 5500 Case: Specifications Fastener Tightening Specifications Accumulator Cover to Case Bolt ........................................................................................................................................ 8.0 - 14.0 Nm (6 - 10 ft. lbs.) Case Extension to Case Bolt ........................................................................................................................................... 42.0 - 48.0 Nm (31 - 35 ft. lbs.) Case Extension to Case Bolt (4WD Shipping) ............................................................................................................ 11.2 - 22.6 Nm (8.3 - 16.7 ft. lbs.) Converter Housing to Case Screw .................................................................................................................................... 65.0 - 75.0 Nm (48 - 55 ft. lbs.) Oil Passage Cover to Case Bolt ............................................................................................................................................. 8 - 14.0 Nm (6 - 10 ft. lbs.) Park Brake Bracket to Case Bolt ..................................................................................................................................... 27.0 - 34.0 Nm (20 - 25 ft. lbs.) Plate to Case Bolt (Shipping) .......................................................................................................................................... 27.0 - 34.0 Nm (20 - 25 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 5501 Case: Service and Repair Heat Shield Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the two bolts securing the transmission heat shield to the transmission. 3. Remove the transmission heat shield from the transmission. Installation Procedure 1. Install the transmission heat shield to the transmission. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the two bolts securing the transmission heat shield to the transmission. Tighten the bolts to 17 Nm (13 ft. lbs.). 3. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 5510 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 5520 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 5534 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 5535 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 5545 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 5546 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications Automatic Transmission Dipstick - Dipstick Tube: Specifications Fastener Tightening Specifications Oil Level Indicator Bolt ......................................................................................................................... .............................................. 47 Nm (35 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications > Page 5554 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Filler Tube and Seal Replacement Removal Procedure 1. Remove the transmission fluid level indicator from the fluid fill tube. 2. Remove the bolt securing the transmission fluid fill tube bracket to the engine. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the bolt securing the transmission fluid fill tube bracket to the transmission. 5. Place a drain pan under the vehicle. 6. Remove the transmission fluid fill tube from the transmission. 7. Remove the transmission fill tube seal. Installation Procedure 1. Install a new oil level indicator tube seal into the transmission case. 2. Install the oil level indicator tube into the seal. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt securing the oil level indicator tube bracket to the transmission. Tighten the bolt to 47 Nm (53 inch lbs.). 4. Remove the drain pan from under the vehicle. 5. Lower the vehicle. 6. Install the bolt securing the oil level indicator tube bracket to the engine. Tighten the bolt to 6 Nm (53 inch lbs.). 7. Fill the transmission with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Transmission Extension Housing Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension 0 ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the case extension bolts (1). Tighten the case extension bolts (1) to 45 Nm (33 ft. lbs.). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 5562 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 5563 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 5564 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 5565 Fluid - A/T: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 4.7L (5.0 Qt) Overhaul ........................... .............................................................................................................................................................. ............... 10.6L (11.0 Qt) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5568 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5569 Fluid - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5570 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5571 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5572 Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid/Filter Replacement Removal Procedure Caution: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the oil pan bolts from the front and sides of the pan only. 6. Loosen the rear oil pan bolts approximately 4 turns. 7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 8. Remove the remaining oil pan bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5576 9. Remove the oil pan and the gasket. 10. Grasp firmly while pulling down with a twisting motion in order to remove the filter. 11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 12. Discard the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: ^ Clutch material ^ Bronze slivers indicating bushing wear ^ Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5577 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the new filter into the case. 4. Install the oil pan and a new gasket. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to 11 Nm (97 inch lbs.). 6. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 5578 Tighten the oil pan drain plug to 18 Nm (13 ft. lbs.). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 5583 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 5584 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 5585 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5586 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the oil cooler lines from the radiator and transmission. Important: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the radiator and transmission. 3. Pull the plastic cap back from the quick connect fitting and down along the cooler line about two inches. 4. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 5. Remove the retaining ring from the quick connect fitting. 6. Discard the retaining ring. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5587 7. Pull the cooler line straight out from the quick connect fitting. 8. Remove the retaining ring (E-clips) securing the cooler line to the quick connect in order to remove the remaining cooler lines from the remaining quick connect fittings. 9. Remove the cooler lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler line to the vehicle. Important: ^ Do not reuse any of the existing oil lines or oil line fittings if there is any excessive corrosion. ^ Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. ^ Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 2. Install a new retaining ring (E-clip) into the quick connect fitting using the following procedure: 3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 4. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5588 5. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 6. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 7. Install the new retaining ring (E-clip) into the remaining quick connect fittings. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. 8. Install the cooler lines to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5589 9. Install the cooler line into the quick connect fitting. 10. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 11. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 12. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. 13. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 14. Ensure that the plastic cap is fully seated against the fitting. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5590 15. Ensure that no gap is present between the cap and the fitting. 16. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 17. A hidden yellow identification band indicates proper joint seating. 18. Install the remaining oil cooler line ends into the transmission and radiator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Fastener Tightening Specifications Oil Pan to Transmission Case Bolt ................................................................................................................................................... 11 Nm (97 inch lbs.) Transmission Oil Pan to Case Bolt ..................................................................................................................................... 9.5 - 13.8 Nm (7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5598 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5599 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5600 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5601 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5602 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5603 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5604 Fluid Pump: Technical Service Bulletins A/T - 4L60-E Oil Pump Identification Bulletin No.: 03-07-30-056 Date: November 05, 2003 INFORMATION Subject: 4L60-E Automatic Transmission Oil Pump First And Second Design Identification Models: 1997-2002 Chevrolet Camaro 1997-2002 Pontiac Firebird 2002-2004 Cadillac Escalade, Escalade EXT 1997-1999 Chevrolet C/K Full Size Pickup 1997-2004 Chevrolet Astro, Blazer, Corvette, Express, S-10, Suburban 1999-2004 Chevrolet Silverado 2000-2004 Chevrolet Tahoe 2002-2004 Chevrolet Avalanche, TrailBlazer 2004 Chevrolet Colorado, SSR 1997-1999 GMC Suburban 1997-2001 GMC Jimmy 1997-2004 GMC Envoy, Safari, Savana, Sierra, Sonoma 1999-2004 GMC Denali 2000-2004 GMC Yukon, Yukon XL 2004 GMC Canyon 1997-2004 Oldsmobile Bravada 2003-2004 HUMMER H2 with 4L60-E Automatic Transmission (RPOs M30, M32, M33) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5605 The purpose of this bulletin is to identify the correct oil pump rotor (212) and slide (203) usage for the two different transmission oil pump designs. Manufacturing of the first design oil pump rotor (212) and slide (203) ended November 30, 2000. Manufacturing of the second design oil pump rotor (212) and slide (203) began December 1, 2000. Important: It is critical that the first and second design oil pump rotors and slides do not become intermixed. Do not use first design pump components with second design pump components. If the pump components from either design are intermixed, pump efficiency will be affected resulting in less than optimal pump performance. The first design oil pump rotor (212) and slide (203) DO NOT have any identification markings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5606 The second design oil pump rotor (212) and slide (203) are identified with dimples (circular depression) as shown above. The rotor (212) has two dimples adjacent to the rotor drive tangs (1). The slide (203) has one dimple located on the spring tab (2). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5607 Fluid Pump: Specifications Fastener Tightening Specifications Pump Assembly to Case Bolt .......................................................................................................................................... 26.0 - 32.0 Nm (19 - 24 ft. lbs.) Pump Cover to Pump Body Bolt ..................................................................................................................................... 20.0 - 27.0 Nm (15 - 20 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5615 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 5624 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 5630 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5635 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5636 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5637 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5638 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5644 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5645 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5646 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 5647 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 5648 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 5649 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 5650 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transmission Extension Housing Rear Oil Seal Replacement Seals and Gaskets: Service and Repair Transmission Extension Housing Rear Oil Seal Replacement Transmission Extension Housing Rear Oil Seal Replacement ^ Tools Required J 21426 Extension Housing Seal Installer - J 36850 Transmission Assembly Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Transmission Extension Housing Rear Oil Seal Replacement > Page 5653 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement ^ Tools Required J 43911 Selector Shaft Seal Remover - J 43909 Selector Shaft Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the Park/Neutral Position (PNP) Switch. 3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. 4. Install the PNP Switch. 5. Lower the vehicle. 6. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 5658 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5662 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5663 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5664 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5665 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5666 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5670 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5671 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator from the steering column jacket assembly. 6. Remove the automatic transmission shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the lower steering column trim cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5679 6. Enable the SIR system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5683 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5684 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Page 5685 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > A/T - Slipping/Missed Shifts Diagnostic Tips Shift Cable: Technical Service Bulletins A/T - Slipping/Missed Shifts Diagnostic Tips File In Section: 07 - Transmission/Transaxle Bulletin No.: 01-07-30-043 Date: December, 2001 INFORMATION Subject: Diagnostic Tips for Slipping or Missing Second, Third and/or Fourth Gear Models: 2001-2002 Chevrolet Camaro, Corvette 2001-2002 Pontiac Firebird 2001-2002 Chevrolet and GMC C/K Pickup and Utility Models (Silverado, Sierra, Suburban, Tahoe, Yukon, Yukon XL) 2001-2002 Chevrolet and GMC G-Van Models (Express, Savana) 2001-2002 Chevrolet and GMC M/L-Van Models (Astro, Safari) 2001-2002 Chevrolet and GMC S/T Pickup and Utility Models (S10, Sonoma, Blazer, Jimmy) 2002 Chevrolet and GMC S/T Utility Models (New Style) (TrailBlazer, Envoy) 2002 Cadillac Escalade 2001-2002 Oldsmobile Bravada Recently, a study was completed to determine the causes of slipping/missing 2nd, 3rd or 4th gear in the 4L60/4L65-E transmission family. This study was conducted using transmissions which were determined by dealership technicians as having a slipping/missing shift. The transmissions used were from vehicles with less than 19,000 km (12,000 mi) and the slipping/missing shift condition was verified during a test drive by dealership personnel before the transmission was removed from the vehicle. Eight items were found to cause the majority of the slipping/missing shift concerns. These eight items are listed below in the order of frequency that they were found. ^ Chips in the servo feed oil passage, orifice # 7 in the spacer plate. ^ Cut forward clutch piston inner seal. ^ Cut 3/4 clutch piston outer seal. ^ Input housing orifice cup plug blown out. ^ Input housing cracked or broken. ^ Mislocated valve body to spacer plate check ball(s). ^ Case damaged at the 2nd clutch apply piston pin bore causing the pin to drag/stick in the bore. ^ Input housing air bleed orifice cup plug with a check ball that does not seal. In addition to the above items, a misadjusted shift cable has been found to cause these types of concerns. When attempting to correct a slipping/missing second, third or fourth gear, the items listed above should be inspected as possible causes. It is also important to reference the appropriate Service Information for additional possible causes of these concerns. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5691 Shift Cable: Specifications Fastener Tightening Specifications Shift Cable Grommet Screw ............................................................................................................................................................ 1.7 Nm (15 inch lbs.) Shift Control Cable Attachment ........................................................................................................................................................... 20 Nm (15 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5692 Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment Adjustment Procedure 1. Ensure that the transmission range selector cable is not restricted. 2. Block the drive wheels. 3. Place the steering column shift lever in the NEUTRAL position. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Ensure that the transmission is in the mechanical neutral position. 6. Disconnect the transmission range selector cable from the transmission range selector lever ball stud. 7. Rotate the transmission range selector lever clockwise until it reaches the full clockwise stop position. 8. Move the range selector lever counterclockwise two detents. 9. Release the locking tab located on the range selector cable. 10. Ensure that the tab remains positioned OUT. 11. Pull the cable end completely forward and release it. (When the cable is pulled completely forward and released, the adjustment spring will position the cable to its most rearward position.) 12. Connect the end of the range selector cable to the transmission range selector lever stud ball. 13. Press the locking tab IN in order to retain the adjustment. 14. Lower the vehicle. 15. Check for proper operation of the range selector cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5693 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement Removal Procedure 1. Block the drive wheels and place the vehicle in the neutral position. 2. Remove the drivers side knee bolster. 3. Remove the bottom half of the steering column trim cover. 4. Remove the range selector cable end from the steering column shift controller ball stud. 5. Remove the clip that secures the range selector cable to the steering column bracket. 6. Remove the range selector cable from the steering column bracket. 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Remove the range selector cable end from the transmission range selector lever stud ball. 9. Remove the clip from the bracket that secures the range selector cable to the transmission. 10. Remove the range selector cable from the bracket. 11. Remove the three range selector cable clips from the body. 12. Remove the grommet from the hole in the floor panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5694 13. If the vehicle is equipped with a transfer case, remove the bolt and washer securing the clip and the range selector cable to the transfer case. 14. Remove the range selector cable from the vehicle. Installation Procedure 1. Feed the steering column end of the range selector cable through the grommet hole in the floor panel. 2. Lower the vehicle. 3. Connect the range selector cable end to the steering column shift controller stud ball. 4. Install the range selector cable to the steering column bracket. 5. Install the clip that secures the range selector cable to the steering column bracket. 6. Raise the vehicle. Refer to Vehicle Lifting. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5695 7. Install the range selector cable to the transmission bracket. ^ Do not depress the adjustment locking tab located on the range selector cable. Ensure that the tab remains positioned OUT. ^ Do not install the range selector cable end to the transmission shift lever stud ball at this time. 8. Ensure that the transmission is in the mechanical neutral position. ^ Rotate the transmission range selector lever clockwise until it reaches the full clockwise stop position. ^ Move the range selector lever counterclockwise two detents. 9. Position the range selector cable to assume a natural routing. The range selector cable must be free to move 20.0 mm (0.80 inch) axially during the adjustment under adjustment spring loads. 10. Pull the range selector cable end completely forward and release it. (When the cable is pulled completely forward and released, the adjustment spring will position the cable to its most rearward position.) Notice: Do not pull the shift lever ball stud forward of the transmission shift lever ball stud during installation. Pulling the shift cable end forward of the transmission shift lever ball stud before installing the shift cable end to the transmission shift lever ball stud will result in a poor adjustment. 11. Connect the end of the range selector cable to the transmission range selector lever stud ball. 12. Press the locking tab IN in order to retain the adjustment and to secure the cable to the transmission bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5696 13. If the vehicle is equipped with a transfer case, install the bolt and washer securing clip and the cable to the transfer case. 14. Install the grommet to the hole in the floor panel. 15. Install the three range selector cable clips to the body. 16. Lower the vehicle. 17. Check for proper operation of the range selector cable. 18. Install the lower half of the steering column trim cover. 19. Install the drivers side knee bolster. 20. Remove the wheel blocks. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 5705 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 5706 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 5712 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 5713 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 5718 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5719 Torque Converter: Specifications Fastener Tightening Specifications Plate to Converter Bolt (Shipping) .................................................................................................................................. 27.0 - 34.0 Nm (20 - 25 ft. lbs.) Torque Converter End Play Specifications 245 mm (9.65 inch) ........................................................................................................................................................ 0.0 - 0.38 mm (0.0 - 0.015 inch) 258 mm (10.16 inch) .................................................................................................................................................. 0.1 0.50 mm (0.004 - 0.020 inch) 298 mm (11.73 inch) .................................................................................................................................................. 0.1 0.48 mm (0.004 - 0.019 inch) 300 mm (11.81 inch) .................................................................................................................................................... 0.1 0.5 mm (0.004 - 0.020 inch) Transmission General Specifications Torque Converter Size, Diameter of Torque Converter Turbine; 245 mm, 258 mm, 298 mm, 300 mm Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 5724 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Fastener Tightening Specifications TCC Solenoid Assembly to Case Bolt ................................................................................................................................ 8.0 - 14.0 Nm (6 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5728 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5729 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5730 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5731 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5732 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications Fastener Tightening Specifications Converter Cover Bolt ........................................................................................................................... ............................................ 10 Nm (89 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5740 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5741 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5742 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5743 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5744 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5745 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 5746 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing/Flow Check Procedures File In Section: 07 - Transmission/Transaxle Bulletin No.: 99-07-30-017A Date: February, 2003 INFORMATION Subject: Automatic Transmission Oil Cooler Flushing and Flow Check Procedures Models: 2003 and Prior GM Light Duty Trucks 2003 HUMMER H2 with Allison(R) Automatic Transmission (RPO M74) This bulletin revises bulletin 99-07-30-017 to reflect the release of the new Transflow(R) J 45096 Transmission Cooling System Service Tool. The Transflow(R) Transmission Cooling System Service Tool is to be used for all vehicles. Please discard Corporate Bulletin Number 99-07-30-017 (Section 07 - Transmission/Transaxle). Refer to Corporate Bulletin Number 02-07-30-052. Important: If you were sent here by the instruction booklet for the J 45096 TransFlow(R) machine, note that the table has been moved to Corporate Bulletin Number 02-07-30-052. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 5750 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Fastener Tightening Specifications Trans Mount to Transmission Bolt ...................................................................................................................................................... 25 Nm (18 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5754 Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Raise the transmission just enough to remove the weight off of the mount. 5. Remove the bolts (1) from the transmission mount. 6. Raise the transmission just enough to remove the mount from between the transmission and the support. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5755 2. Install the bolts (1) that retain the transmission mount to the transmission (2WD), or transfer case adapter (AWD). For vehicles equipped with AWD, tighten the bolts to 47 Nm (35 ft. lbs.). For vehicles equipped with 2WD, tighten the bolts to 50 Nm (37 ft. lbs.). 3. Lower the transmission. 4. Install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to 40 Nm (30 ft. lbs.). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5759 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5760 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5761 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5762 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5763 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5767 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5768 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 5780 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5790 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5791 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5792 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5793 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5794 Left Side Control Valve Body Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5795 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5796 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5797 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-038D > Sep > 06 > A/T - Poor Performance/MIL ON/DTC P0757 > Page 5802 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5807 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5808 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5809 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5819 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5820 Valve Body Spring and Bore Plug Chart (inch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5821 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5822 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5823 Left Side Control Valve Body Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5824 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5825 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 07-07-30-024 > Sep > 07 > A/T - Valve Body Reconditioning > Page 5826 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Valve Body: All Technical Service Bulletins A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis Bulletin No.: 01-07-30-030B Date: October 18, 2005 INFORMATION Subject: 4L60-E/4L65-E Automatic Transmission Diagnostic Information on Harsh 1-2 Upshift Models: 2001-2006 GM Passenger Cars and Light Duty Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60-E or 4L65-E Automatic Transmission Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 01-07-30-030A (Section 07 - Transmission/Transaxle). The following four conditions have been found to cause the majority of consistent, harsh 1-2 shift comments. ^ Chips/Sediment/Debris/Contamination found in the valve body, 1-2 accumulator valve (371) bore, may cause the 1-2 accumulator valve to stick or hang-up. ^ Chips/Sediment/Debris/Contamination found in the valve body, 4-3 sequence valve (383) bore, may cause the 4-3 sequence valve to stick or hang-up. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5831 A cracked 1-2 accumulator piston (56) that is allowing fluid to leak by. Mislocated/Missing valve body-to-spacer plate check balls (61). When attempting to correct a consistent harsh 1-2 shift, the four conditions listed above should be inspected as possible causes. It is important to also refer to the appropriate Service Manual for further possible causes of this condition. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5832 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-030B > Oct > 05 > A/T - 4L60-E/4L65-E Harsh 1-2 Upshift Diagnosis > Page 5833 This diagnostic table should be used when addressing a harsh 1-2 shift concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5834 Valve Body: Specifications Fastener Tightening Specifications Valve Body to Case Bolt ..................................................................................................................................................... 8.0 14.0 Nm (6 - 10 ft. lbs.) Transmission Fluid Pressure Manual Valve Position Switch to Valve Body Bolt ............................................................... 8.0 - 14.0 Nm (6 - 10 ft. lbs.) Pressure Control Solenoid Bracket to Valve Body Bolt ..................................................................................................... 8.0 - 14.0 Nm (6 - 10 ft. lbs.) Detent Spring to Valve Body Bolt .................................................................................................................................. 20.0 - 27.0 Nm (15 - 20 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5835 Valve Body: Service and Repair Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. Important: The following components can be serviced without removing the valve body from the transmission: ^ The torque converter clutch solenoid (1) ^ The pressure control solenoid (2) ^ The internal wiring harness (3) ^ The 2-3 shift solenoid (4) ^ The 1-2 shift solenoid (5) ^ The transmission fluid pressure manual valve position switch (6) ^ The 3-2 shift solenoid (7) ^ The Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the oil pan, gasket, and filter. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5836 6. Remove the fluid indicator stop bracket bolt (2). 7. Remove the fluid indicator bracket (1). 8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts. 10. Remove the TCC solenoid retaining bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5837 11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. 12. Reposition the harness to the side of the transmission case. 13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. 14. Remove the transmission fluid pressure switch. 15. Inspect the transmission fluid pressure switch for damage or debris. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5838 16. Remove the manual detent spring retaining bolt. 17. Remove the manual detent spring. 18. Inspect the manual detent spring for cracks or damage. Important: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages. 19. Remove the remaining control valve body bolts. 20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. Installation Procedure 1. Install the checkballs (1 - 7) in the valve body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5839 2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. 3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5840 5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: ^ M6 X 1.0 X 65.0 (1) ^ M6 X 1.0 X 54.4 (2) ^ M6 X 1.0 X 47.5 (3) ^ M6 X 1.0 X 35.0 (4) ^ M8 X 1.0 X 20.0 (5) ^ M6 X 1.0 X 12.0 (6) ^ M6 X 1.0 X 18.0 (7) 6. Install the manual detent spring. 7. Install but do not tighten the manual detent spring retaining bolt. 8. Install the transmission fluid pressure switch. 9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5841 Notice: Refer to Fastener Notice in Service Precautions. Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the control valve body bolts (in sequence) to 11 Nm (97 inch lbs.). 11. Ensure that the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to 11 Nm (97 inch lbs.). 12. Install the TCC solenoid with a new O-ring seal to the valve body. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5842 13. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5843 16. Install the TCC PWM solenoid (1) to the control valve body. 17. Install the TCC PWM solenoid retainer (2). 18. Install the transmission fluid indicator stop bracket (1) and bolt (2). Tighten the transmission fluid indicator stop bracket bolt to 11 Nm (97 inch lbs.). 19. Connect the internal wiring harness electrical connectors to the following components: ^ The transmission fluid pressure manual valve position switch (1) ^ The 1-2 shift solenoid (2) ^ The 2-3 shift solenoid (3) ^ The pressure control solenoid (4) ^ The TCC PWM solenoid (5) ^ The 3-2 shift solenoid (6) 20. Install the transmission oil pan and filter. 21. Lower the vehicle. 22. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > System Information > Technical Service Bulletins > M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Clean the rear axle cover area. 3. Remove the rear axle cover bolts. Place a container under the axle housing in order to retrieve the lubricant. 4. Remove the rear axle cover from the axle housing. Pry the rear axle cover loose. 5. Drain the lubricant from the axle housing. 6. Remove the fill plug. 7. Clean the gasket surfaces on the axle housing and the rear axle cover. Installation Procedure 1. Install the new gasket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Page 5858 2. Install the rear axle cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear axle cover bolts. Tighten the bolts to 30 Nm (22 ft. lbs.) in a crosswise pattern. 4. Add axle lubricant to the axle housing. Use the proper fluid. 5. Install the fill plug. Tighten the fill plug to 33 Nm (24 ft. lbs.). 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications Differential Axle Housing: Specifications Fastener Tightening Specifications Differential Housing Cover Bolts ........................................................................................................................................................ 30 Nm (22 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications > Page 5862 Differential Axle Housing: Service and Repair Rear Axle Housing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. 3. Remove the rear axle assembly. 4. Remove the brake drums. 5. Remove the rear axle cover housing and gasket. 6. Remove the axle shafts. 7. Remove the brake backing plates. 8. Remove the differential. 9. Remove the drive pinion. 10. Remove the drive pinion shaft yoke and the seal. Installation Procedure 1. Install the drive pinion. 2. Install the differential case. 3. Adjust the side bearing preload. 4. Adjust the backlash. 5. Perform a gear tooth contact pattern check. 6. Install the brake backing plates. 7. Install the axle shafts. 8. Install the rear axle housing cover and gasket. 9. Install the brake drums. 10. Install the rear axle. 11. Fill the axle with lubricant. 12. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications Fastener Tightening Specifications Fill Plug ................................................................................................................................................ ............................................... 33 Nm (24 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Differential Oil Capacity Capacity ............................................................................................................................................... .................................................................... 3.5 Pints Front Differential Differential Oil Capacity Front .................................................................................................................................................... .......................................................... 1.2L (2.6 Pints) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5870 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Front Grade ......................................................................................................................................... .................................................................................... GL-5 Viscosity ................................................ .............................................................................................................................................................. ..... 80W-90 Rear Grade ...................................................................................................................... ................................................................................................. Synthetic Viscosity ............................. .............................................................................................................................................................. ........................ 75W-90 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check Fluid - Differential: Service and Repair Lubricant Level Check Lubricant Level Check 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. Specification The lubricant level should be between 0 - 10 mm (0 - 0.4 inch) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check > Page 5873 Fluid - Differential: Service and Repair Lubricant Change Lubricant Change Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover and the rear axle housing cover gasket. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure 1. Install the new rear axle housing cover gasket and the rear axle housing cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Lubricant Level Check > Page 5874 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear axle housing cover bolts. Tighten the rear axle housing cover bolts to 30 Nm (22 ft. lbs.). 3. Fill the rear axle. Use the proper fluid. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 ft. lbs.). 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications Pinion Bearing and Differential Bearing Preload Pinion and Differential Case Bearing Preload, New Bearings ......................................................................................... 3.4 - 6.2 Nm (30 - 55 inch lbs.) Pinion and Differential Case Bearing Preload, Used Bearings ........................................................................................ 2.8 - 5.6 Nm (25 - 50 inch lbs.) Pinion Bearing Preload, New Bearings ........................................................................................................................... 1.7 - 3.4 Nm (15 - 30 inch lbs.) Pinion Bearing Preload, Used Bearings ........................................................................................................................... 1.1 - 2.8 Nm (10 - 25 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications Fastener Tightening Specifications Ring Gear Bolts ................................................................................................................................... .............................................. 120 Nm (89 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair Rear Oil Seal and/or Bearing Replacement ^ Tools Required J 8092 Driver Handle - J 23771 Axle Shaft Seal Installer - J 34794 Bearing Installer - J 23689 Axle Shaft Bearing Remover - J 2619-01 Slide Hammer Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 23689 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 34794 (1) and the J 8092 (2). Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 2. Install the axle shaft seal using the J 23771. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 5884 3. Install the axle shaft. 4. Install the rear axle housing cover. 5. Install the tire and wheel assembly. 6. Fill the rear axle. Use the proper fluid. 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Vibration Damper: Customer Interest Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5893 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5894 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5895 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > Customer Interest for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5896 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Vibration Damper: All Technical Service Bulletins Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5902 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5903 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5904 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Vibration Damper, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vibration Damper: > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 5905 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair Axle Shaft Assembly: Service and Repair Rear Axle Shaft Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drums. 4. Remove the rear cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Page 5910 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock (4) from the button end of the axle shaft (1). Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. 11. Remove the axle shaft (1) from the housing (5). Installation Procedure Important: Carefully insert the axle shaft in order to not damage the seal. 1. Install the axle shaft (1) into the rear axle housing (5). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Page 5911 2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1). 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the lock in the differential gear. 7. Align the hole in the pinion shaft with the bolt hole in the differential case. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the new pinion shaft locking bolt. Tighten the pinion shaft locking bolt to 25 Nm (19 ft. lbs.). 9. Install the rear cover and the gasket. 10. Install the brake drums. 11. install the tire and wheel assembly. 12. Fill the rear axle. Use the proper fluid. 13. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5925 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5926 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5927 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) - Tools Required J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5933 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle - Classify the failure of the wheel bearing with the aid of the illustrations. - Determine the cause of the wheel bearing failure. - Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5934 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5935 Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5936 Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears The smearing of the metal is due to slippage. Slippage can be caused by the following factors: Poor fits - Lubrication - Overheating - Overloads - Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5937 Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5938 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 5939 Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5940 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Page 5941 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications wheel hub nut 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Fastener Tightening Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5950 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The Propeller Shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A one piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models which are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. When the design angles are exceeded, the operational life of the joint decreases. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures/- Symptoms Propeller Shaft Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5953 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures - Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: ^ Leaks ^ Noises ^ Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Diagnostic Starting Point Vibration Diagnosis and Correction. Visual/Physical Inspection ^ Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Leak at Front Slip Yoke See: Leak at Front Slip Yoke ^ Universal Joint Noise See: Universal Joint Noise ^ Ping, Snap, or Click Noise See: Ping, Snap, or Click Noise ^ Knock or Clunk Noise See: Knock or Clunk Noise ^ Scraping Noise See: Scraping Noise ^ Squeak Noise See: Squeak Noise Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5954 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Page 5955 Drive/Propeller Shaft: Service and Repair Propeller Shaft Replacement - Rear Removal Procedure Important: The driveline components in this vehicle are factory system-balanced. System balance provides a smoother running driveline operation. Observe the position of all the driveline components. Accurately mark the relationship of the components before removal. These components include the propeller shafts, the drive axles, the pinion flanges, and the output shafts. All components must be reassembled in the exact relationship to each other as they were before removal. Follow the specifications, the torque values, and any measurements made prior to disassembly in order to maintain the factory system balance. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Accurately reference mark the propeller shaft. 3. Remove the bolts from the rear of the pinion flange. 4. Remove the retainers. Important: Do not pound on the original propeller shaft yoke ears. The injection joints may fracture. Never pry or place any tool between a yoke and a universal joint. 5. Remove the yoke and cross assembly. 6. Tape the bearing cups in order to prevent the loss of bearing rollers. 7. Remove the propeller shaft by using the following procedure: 7.1. Slide the propeller shaft forward. 7.2. Lower the propeller shaft and remove under the rear axle. 7.3. Do not allow the universal joint to incline greatly; the joint may fracture. 8. Clean all the parts with a suitable solvent. 9. Inspect the outer diameter of the nylon injected yoke for burrs. Burring damages the transmission seal. 10. Inspect for proper installation and uniform seating of the bearing cups. 11. Inspect the slip yoke splines for wear. 12. Inspect for twisted slip yoke splines or possibly the wrong universal joint. Replace the parts as necessary. Installation Procedure 1. Install the propeller shaft into the transmission. Important: Install a new universal joint whenever a slip joint or companion flange is serviced. 2. Lubricate the slip joint. 3. Install the yoke and cross assembly onto the pinion flange. 4. Align the reference marks on the pinion flange and the propeller shaft rear yoke. Seat the yoke properly. 5. Install the retainers. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Page 5956 6. Install the bolts into the pinion flange. Tighten the bolts to 36 Nm (27 ft. lbs.). 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Page 5957 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Removal Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Remove the propeller shaft. 2. Support the propeller shaft in a line horizontal with the table of a press. 3. Mark the propeller shaft in order to show which end connects to the transmission or transfer case and which end connects to the rear or front axle. 4. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 5. In order to shear the plastic retaining ring on the bearing cup, place the J 9522-3 on the on the open horizontal bearing cups and press the lower bearing cup out of the yoke ear. 6. If the bearing cup is not completely removed, lift the cross, and insert J 9522-5 between the seal and bearing cup being removed. Continue pressing the bearing cup out of the yoke. 7. Rotate the propeller shaft and press the opposite bearing cup out of the yoke. 8. Disassemble the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5962 10. If you are replacing the front universal joint (rear axle only), remove the bearing cups in the slip yoke in the same manner. 11. Inspect the retaining ring grooves for plastic. 12. Inspect the bearing cup bores for burrs or imperfections. 13. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 14. The sheared plastic may prevent the bearing cups from being pressed into place and thus prevent the bearing retainers from being properly seated. Installation Procedure 1. Remove the bearing cups from the new universal joint journals. 2. Coat the needle bearings in the bearing cups with a thin layer of chassis grease. Use your finger to apply the grease. 3. Install one bearing cup part way into one side of the yoke. 4. Turn the yoke ear towards the bottom. 5. Install the cross into the yoke so that the trunnion seats freely into the bearing cup. 6. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until it is flush with the yoke ear. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5963 7. Install the opposite bearing cup part way into the yoke ear. Make sure that the trunnions are started straight and true into both bearing cups. Important: If the bearing cup seems to bind or hang-up, stop pressing. Check the needle bearings for misalignment in the bearing cup. 8. Press the opposite bearing cup into the yoke ear. ^ Work the cross all the time. ^ Check for free unbinding movement of the trunnions in the bearing cups. ^ Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. 9. Install the bearing retainer in the retainer groove. ^ Continue pressing until you can snap both retainers into place. ^ A small amount of chassis grease may help the snap ring seat in the bearing cup groove. 10. It the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer. 11. Install the propeller shaft. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5964 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring ^ Tools Required J 9522-3 U Joint Bearing Separator - J 9522-5 U Joint Bearing Spacer Remover Removal Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Remove the propeller shaft. 2. Support the propeller shaft in a line horizontal with the table of a press. 3. Mark the propeller shaft in order to show which end connects to the transmission or transfer case and which end connects to the rear or front axle. 4. Remove the snap rings. ^ Pinch the ends of the snap ring together with a pair of pliers. ^ If a snap ring does not readily snap out of the groove in the yoke, tap the end of the bearing cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 inch) socket. 6. Press the lower bearing cup out of the yoke ear. Use the J 9522-3. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5965 7. If the bearing cup is not completely removed, do the following: 7.1. Lift the cross and insert the J 9522-5 between the seal and the bearing cup. 7.2. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft and press the opposite bearing cup out of the yoke. 9. Remove the cross from the yoke. 10. Remove the remaining universal joint parts from the yoke. 11. If you are replacing the front universal joint (rear axle only), remove the bearing cups in the slip yoke in the same manner. 12. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 13. Inspect the bearing cup bores for burrs or imperfections. Important: Corrosion or dirt may prevent the bearing cup installation and may prohibit the proper seating of the bearing retainers. 14. Clean the retaining ring grooves. Installation Procedure 1. Remove the bearing cups from the new universal joint journals. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5966 2. Coat the needle bearings in the bearing cups with a thin layer of the grease that is present on the journal. Use your finger to apply the grease. 3. Install one bearing cup part way into one side of the yoke. 4. Turn the yoke ear towards the bottom. 5. Install the cross into the yoke so that the trunnion seats freely into the bearing cup. 6. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until it is flush with the yoke ear. 7. Install the opposite bearing cup part way into the yoke ear. 8. Make sure that the trunnions are started straight and true into both bearing cups. Important: If the bearing cup seems to bind or hang-up, stop pressing. Check the needle bearings for misalignment in the bearing cup. 9. Press the opposite bearing cup into the yoke ear. ^ Work the cross all the time. ^ Check for free unbinding movement of the trunnions in the bearing cups. ^ Press the bearing cup into the yoke until the bearing retainer groove is visible over the top of the bearing cup. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joint Replacement - Nylon Injected Ring > Page 5967 10. Install the bearing retainer in the retainer groove. ^ Continue pressing until you can snap both retainers into place. ^ A small amount of chassis grease may help the snap ring seat in the bearing cup groove. 11. If the retainer does not seat, spring the yoke slightly with a firm blow from a dead blow hammer. 12. Install the propeller shaft. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Engine Flywheel Bolt ........................................................................................................................... ............................................................... 74 ft. lbs. Flywheel to Torque Converter Bolt ...................... .............................................................................................................................................. 46 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5971 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the transmission assembly. 2. Remove the bolts and the engine flywheel. 3. Clean and inspect all parts. Installation Procedure 1. Install the engine flywheel to the crankshaft. 2. Align the locator hole to the pin. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5972 3. Install the engine flywheel bolts. Tighten the engine flywheel bolts in sequence to 100 Nm (74 ft. lbs.). 4. Install the transmission assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 5977 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 5983 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5987 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5988 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5989 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5990 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5991 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5995 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5996 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and filter. 3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 7. Remove the pressure regulator valve (1). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 6006 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission oil filter and pan. 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the lower steering column trim cover. 3. Disconnect the automatic transmission shift lock control actuator electrical connector. 4. Place the shift lever clevis into the neutral position. 5. Use a small screwdriver to pry the automatic transmission shift lock control actuator from the steering column jacket assembly. 6. Remove the automatic transmission shift lock control actuator from the steering column. Installation Procedure 1. Firmly install the automatic transmission shift lock control actuator onto the steering column jacket assembly. 2. Connect the automatic transmission shift lock control actuator electrical connector. 3. Adjust the automatic transmission shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 3.1. Pull out the tab (1) on the adjuster block side (2) of the automatic transmission shift lock control actuator. 3.2. Press on the adjuster block (2) to disengage the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3.3. Lock the adjuster block in place by pushing inward on the tab (1). 4. Inspect the automatic transmission shift lock control actuator for the following items: 4.1. The automatic transmission shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the PARK position. 4.2. Turn the ignition to the ON position and depress the brake pedal in order to move the gear shift lever out of the PARK position. The actuator will be energized. 4.3. Readjust the automatic transmission shift lock control actuator if needed. 5. Install the lower steering column trim cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 6010 6. Enable the SIR system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission oil pan and filter. Important: Do not remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer. 5. Remove the pressure control solenoid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6014 6. Remove the 1-2 and 2-3 shift solenoid retainers. 7. Remove the 1-2 and 2-3 shift solenoids. 8. Remove the 3-2 control solenoid retainer. 9. Remove the 3-2 control solenoid. Installation Procedure 1. Install the 3-2 control solenoid. 2. Install the 3-2 control solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6015 3. Install the 1-2 and 2-3 shift solenoids. 4. Install the 1-2 and 2-3 shift solenoid retainers. 5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 7. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 8. Install the 1-2 accumulator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Page 6016 9. Install the transmission oil pan and filter. 10. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Fastener Tightening Specifications TCC Solenoid Assembly to Case Bolt ................................................................................................................................ 8.0 - 14.0 Nm (6 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6020 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid, TCC Solenoid, and Wiring Harness ^ Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the transmission oil pan and the filter. 3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. 5. Disconnect the internal wiring harness electrical connectors from the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6021 6. Remove the TCC PWM solenoid retainer. 7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. 8. Remove the pressure control solenoid retainer. 9. Remove the pressure control solenoid. 10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6022 11. Using J 28458, release the pass-through electrical connector from the transmission case. 11.1. Use the small end of the J 28458 over the top of the connector. 11.2. Twist in order to release the four tabs retaining the connector. 11.3. Pull the harness connector down through the transmission case. 12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. 13. Inspect the TCC solenoid and wiring harness assembly for the following defects: ^ Damage ^ Cracked connectors ^ Exposed wires ^ Loose pins Installation Procedure 1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6023 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. ^ Tighten the control valve body retaining bolts to 11 Nm (97 inch lbs.). ^ Tighten the TCC solenoid retaining bolts to 11 Nm (97 inch lbs.). 4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. 5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to 11 Nm (97 inch lbs.). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6024 8. Connect the internal wiring harness electrical connectors to the following components: ^ Transmission fluid pressure switch (1) ^ 1-2 shift control solenoid (2) ^ 2-3 shift control solenoid (3) ^ Pressure control solenoid (4) ^ TCC PWM solenoid (5) ^ 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission oil pan and filter. 12. Lower the vehicle. 13. Fill the transmission to the proper level with DEXRON III transmission fluid. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection Tow/Haul Switch/Indicator Always On or Inoperative Circuit Description Tow/haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the Body Control Module (BCM) is momentarily toggled to zero volts. This signals the Powertrain Control Module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again disables tow/haul mode and returns the transmission to a normal shift pattern. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection > Page 6030 Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a faulty tow/haul switch. 3. This step tests for voltage input from the BCM to the tow/haul switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Fastener Tightening Specifications Park/Neutral Position Switch Screw ................................................................................................................................................... 3 Nm (27 inch lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6034 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch Connector, Wiring Harness Side Tow/Haul Switch Connector, Column Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6035 Park/Neutral Position Switch (C1) Park/Neutral Position Switch (C2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6036 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: ^ The following procedure is for vehicles that have not had the switch removed or replaced. If the switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. ^ Apply the parking brake. ^ The engine must start in the P (Park) or N (Neutral) positions only. ^ Check the switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the N (Neutral) position. 2. With an assistant in the drivers seat, raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position switch mounting bolts. 4. With the vehicle in the N (Neutral) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the bolts securing the switch to the transmission. Tighten the bolts to 25 Nm (18 ft. lbs.). 7. Lower the vehicle. 8. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. 9. Replace the park/neutral position switch if proper operation can not be achieved. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6037 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement ^ Tools Required J 41364-A Neutral Position Adjustment Tool Removal Procedure 1. Apply the parking brake. 2. Shift the transmission into neutral. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Remove the nut securing the transmission control lever to the manual shaft. 5. Remove the transmission control lever from the manual shaft. 6. Disconnect the electrical connectors from the switch. 7. Remove the bolts securing the park/neutral position switch to the transmission. 8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure 1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary. 3. Install the switch to the transmission with two bolts finger tight. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6038 4. Position the tool J 41364-A onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice in Service Precautions. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to 25 Nm (18 ft. lbs.). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Connect the electrical connectors to the switch. 8. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to 25 Nm (18 ft. lbs.). 9. Lower the vehicle. 10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Fastener Tightening Specifications Speed Sensor Retainer Bolt ............................................................................................................................................ 10.5 13.5 Nm (7.7 - 10 ft. lbs.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6042 VSS Assembly Connector, Wiring Harness Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6043 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement ^ Tools Required J 38417 Speed Sensor Remover Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the harness connector. 3. Remove the bolt. 4. Place a drain pan under the vehicle. 5. Remove the vehicle speed sensor using J 38417. 6. Remove the O-ring seal. Installation Procedure 1. Install the new speed sensor and O-ring seal using J 38417 2. Coat the seal with a thin film of transmission fluid. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolt. Tighten the bolt to 11 Nm (97 inch lbs.). 4. Install the harness connector. 5. Lower the vehicle. 6. Refill the fluid as required. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The electronic brake control module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EBCM to BPMV 39 inch lbs. Front Brake Lines to BPMV 18 ft. lbs. Rear Brake Line to BPMV 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6055 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6056 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6057 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6058 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the 4 T-25 Tort mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6059 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 new T-25 Torx screws (1) in the EBCM (2). ^ Tighten the 4 T-25 Torx screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS on. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU (1) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the 2 electrical harness connectors from the EBCM. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect 5 brake lines from the BPMV. 4. Slide the EHCU (1) off of the frame bracket (2). 5. Remove 2 bolts (4) securing the BPMV mounting bracket (3) to the BPMV (5). 6. Disconnect the 2-way ABS pump motor connector. 7. Remove the 4 T-25 Torx bolts (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 8. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 9. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6063 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the 4 EBCM bolts (1). ^ Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2-way ABS pump motor connector to the EBCM. 4. Install the BPMV (5) to the BPMV mounting bracket (3) with the 2 bolts (4). 5. Slide the EHCU (1) back onto the frame bracket (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the EHCU (1). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). 8. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the 2 nuts (4). 9. Bleed the brake system. 10. Return to Diagnostic System Check - ABS. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 6072 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 6078 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6079 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6080 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6081 Wheel Speed Sensor: Diagrams Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6082 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD) Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the brake caliper (1). 4. Remove the hub and rotor assembly (3). 5. Remove the wheel speed sensor cable electrical connector (2). 6. Remove the wheel speed sensor harness clip rivets using a 3/16 inch drill bit. 7. Remove the clips from the wheel speed sensor wire. Save the clips for the replacement sensor. 8. Remove the wheel speed sensor mounting bolts and nut. 9. Remove the 2 splash shield mounting bolts (7). 10. Remove the wheel speed sensor and the splash shield assembly (6). 11. Remove the splash shield gasket. 12. Clean the gasket and knuckle (8) surfaces thoroughly with a dry cloth. Installation Procedure 1. Install the splash shield gasket. 2. Install the wheel speed sensor splash shield (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). 4. Install the wheel speed sensor mounting bolts and nut. ^ Tighten the speed sensor mounting bolts to 26 Nm (19 ft. lbs.). 5. Install the harness clips to the wheel speed sensor wire. Locate the clips at the paint dots on the wire. 6. Install the harness clips with 3/16 inch rivets. 7. Connect the wheel speed sensor electrical connector (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6083 8. Install the hub and rotor (3). 9. Install the brake caliper (1). 10. Install the tire and wheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting (Leak Testing the Hydraulic Brake System) 10 psi Pressure Bleed Procedure Setting 35 psi Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two Person Procedure Important: ^ Use the 2-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to one full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid that is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6089 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM PIN 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 17.1. Inspect the brake system for external leaks. 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6090 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6091 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177 Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J 39177, or equivalent to the metering valve. 6. Using the J 39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J41613 to the J29567. 8. Install the J41618 and J29567to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J29532, or equivalent, to the J 29567. 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6092 valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J29567 from the brake master cylinder reservoir. 23. Remove the J 39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6093 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the halfway point with Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake Pedal Bracket Bolt 26 ft. lbs. Brake Pedal Pivot Bolt 33 ft. lbs. Brake Pedal Maximum Travel* Hydraulic Power Assist 2.83 in. *Specification with 100 lbs. of force applied to the brake pedal, the ignition Off, and the brake booster power reserve depleted. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6097 Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the booster pushrod (4) and stop lamp switch (2) from brake pedal (1). 2. Detach and pivot the instrument panel down to access the brake pedal mounting bolt. 3. Remove the nut from the brake pedal pivot bolt. 4. Remove the brake pedal pivot bolt. 5. Remove the brake pedal (1), spacers and bushings from the vehicle. Installation Procedure 1. Install the brake pedal (1) to the vehicle. 2. Install the through bolt, spacers and bushings to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nut to the brake pedal pivot bolt. ^ Tighten the nut to 45 Nm (33 ft. lbs.). 4. Pivot and attach the instrument panel. 5. Install the booster pushrod (4) and the stop lamp switch (2) to the brake pedal (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation Brake Warning Indicator The instrument panel cluster (IPC) illuminates the brake warning indicator when the following occurs: ^ The body control module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The EBCM detects a low brake fluid condition and sends a class 2 message to the IPC. ^ The IPC performs the bulb check. ^ An ABS-disabling malfunction also disables dynamic rear proportioning (DRP). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 6101 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Brake Caliper Bleeder Valve (Front) 115 inch lbs. Brake Caliper Bleeder Valve (Rear) 115 inch lbs. Caliper Mounting Bolts 38 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection Brake Caliper: Service and Repair Brake Caliper Inspection Brake Caliper Inspection 1. Inspect the brake caliper housing (1) for cracks, excessive wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper piston(s) into the caliper bore(s). The movement of the caliper piston(s) into the caliper bore(s) should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. ^ For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. ^ For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6108 Brake Caliper: Service and Repair Brake Caliper Overhaul Brake Caliper Overhaul ^ Tools Required J 26267 Piston Seal Installer Removal Procedure 1. Remove the caliper. 2. Drain all the brake fluid from the caliper. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Pad the interior of the caliper with clean shop towels. 4. Remove the piston from the caliper bore. 5. Remove the boot from the caliper bore. Do not scratch the housing bore. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6109 6. Remove the piston seal from the caliper bore. Do not use a metal tool. 7. Remove the bleeder valve from the caliper body. 8. Clean the bleeder valve, the caliper bore, the caliper passages and the piston with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Inspect the piston and the caliper for the following conditions: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore 10. Replace the piston or the caliper if you found any of the above conditions. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6110 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6111 5. Install the boot into the caliper housing bore using the J 26267. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve in the caliper body. ^ Tighten the bleeder valve to 13 Nm (115 inch lbs.). Important: Before moving the vehicle, pump the brake pedal until it is firm. Check the brake fluid level in the master cylinder after pumping the brakes. 7. Install the caliper. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6112 Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and hand tighten a wheel lug nut in order to retain the rotor (A4WD only). 7. Compress the front caliper piston. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor. ^ Remove the C-clamp from the caliper. 8. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 9. Plug the opening in the front brake hose (2) in order to prevent excessive brake fluid loss and contamination. Do not pinch off the brake hose with any tools. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6113 10. Remove the caliper mounting bolts. 11. Remove the caliper. 12. Remove the brake pads. 13. Remove the bushings. 14. Remove the sleeves (RWD only). 15. Inspect the caliper bolts for corrosion or damage. Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6114 4. Install the bushings. 5. Install the sleeves (RWD only). 6. Install the brake pads. 7. Install the caliper assembly. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the mounting bolts. ^ Tighten the bolts to 51 Nm (38 ft. lbs.). Important: Install NEW copper brake hose gaskets. 9. Install the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). 10. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 44 Nm (32 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6115 11. Remove the wheel lug nut securing the rotor to the hub. 12. Measure the clearance between the caliper and the steering knuckle. Measure the clearance at each end of the caliper individually and then add the measurements together. Specification The total should be 0.26 - 0.60 mm (0.010 - 0.024 in). ^ If the total clearance between the caliper and the steering knuckle is less than 0.26 mm (0.010 in), file the steering knuckle equally on each side until the proper clearance is obtained. ^ If the total clearance between the caliper and the steering knuckle is more than 0.60 mm (0.024 in), inspect the brake caliper and the steering knuckle for damage and replace as needed. 13. Install the tire and wheel. 14. Lower the vehicle. 15. Fill the master cylinder to the proper level with clean brake fluid. 16. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum Thickness Minimum Thickness Disc Brake Pad 0.030 in Replace the disc brake pads when the friction surface is worn to within 0.030 in of the mounting plates. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 6119 Brake Pad: Service Precautions Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Brake Pads Replacement Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Only on the A4WD, install and hand tighten a wheel lug nut in order to retain the rotor. 7. Compress the front caliper piston, with the following procedure: 7.1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 7.2. Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor. 7.3. Remove the C-clamp from the caliper. Notice: Refer to Support the Brake Caliper While Flex Hose is Connected Notice in Service Precautions. Important: DO NOT disconnect the hydraulic brake flexible hose from the caliper. 8. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6122 9. Only on the RWD, remove the inboard brake pad. 10. Only on the RWD, remove the retainer spring. 11. Only on the RWD, remove the outboard brake pad. 12. Only on the A4WD, remove the inboard and outboard brake pads. 13. Inspect the following parts for cuts, tears, or deterioration: ^ The disc brake mounting hardware ^ The caliper dust boot 14. Replace any damaged parts. Important: Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper. 15. Inspect the caliper bolts for corrosion or damage. Installation Procedure Important: Do not damage the piston or the caliper boot. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6123 1. Using a C-clamp (1), bottom the piston into the caliper bore. Use an old brake pad or wooden block (2) placed across the face of the piston. 2. Only on the A4WD, install the inboard brake pad. 3. Only on the A4WD, install the outboard brake pad. 4. Only on the RWD, install the retainer spring onto the inboard brake pad. 5. Only on the RWD, install the inboard brake pad. 6. Only on the RWD, install the outboard brake pad. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6124 7. Only on the RWD, compress the outboard pad ears to the caliper. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the caliper mounting bolts. ^ Tighten the bolts to 51 Nm (38 ft. lbs.). 9. Only on the A4WD, remove the wheel lug nut securing the rotor to the hub. 10. Install the tire and wheel. 11. Lower the vehicle. 12. With the engine OFF, gradually apply the brake pedal approximately 2/3 of the pedal's travel distance. 13. Slowly release the brake pedal. 14. Wait 15 seconds, then repeat steps 12-13 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 15. Fill the brake master cylinder to the proper level. 16. Burnish the pads and rotors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 6125 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6130 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6131 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6132 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6133 WARRANTY INFORMATION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6134 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6135 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6136 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6137 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6138 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6139 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6140 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6141 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6142 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 6143 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 6144 Brake Rotor/Disc: Specifications Rotor Maximum Allowable Radial Runout 0.006 in Rotor Maximum Allowable Scoring 0.059 in Splash Shield Bolts 12 ft. lbs. M-Van (RWD) Rotor Discard Thickness* 0.965 in *All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum or discard thickness specifications. Rotor Minimum Allowable Thickness After Refinish 0.980 in Rotor Thickness (new) 1.04 in Rotor Maximum Allowable Lateral Runout 0.002 in Rotor Maximum Allowable Scoring 0.059 in Rotor Maximum Allowable Thickness Variation (0.001 in L-Van (A4WD) Rotor Discard Thickness* 1.215 in *All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum or discard thickness specifications. Rotor Minimum Allowable Thickness After Refinish 1.23 in Rotor Thickness (new) 1.25 in Rotor Maximum Allowable Lateral Runout 0.002 in Rotor Maximum Allowable Scoring 0.059 in Rotor Maximum Allowable Thickness Variation 0.001 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 6145 Brake Rotor/Disc: Service Precautions Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Brake Rotor Replacement Removal Procedure Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Use Goodwrench Brake Parts Cleaner, GM P/N 123777981, or the equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents that may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the brake caliper. 4. Remove the rotor (RWD only). 5. Remove the rotor (A4WD only). 6. Inspect all of the parts. Replace any damaged or corroded parts. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 6148 1. Install the rotor to the hub and bearing assembly (A4WD only). 2. Install the rotor to the steering knuckle (RWD only). 3. Install the brake caliper. 4. Install the tire and wheel assembly. Important: Before moving the vehicle, pump the brake pedal until it is firm. Check the brake fluid level in the master cylinder after pumping the brakes. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 6149 Brake Rotor/Disc: Service and Repair Disc Brake Splash Shield Replacement- Front Disc Brake Splash Shield Replacement- Front Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the two wheel hub and bearing mounting bolts that secure the splash shield to the spindle. 5. Remove the splash shield. Installation Procedure 1. Install the splash shield. Notice: Refer to fastener Notice in Service Precautions. 2. Install the two wheel hub and bearing mounting bolts that secure the splash shield to the spindle. ^ Tighten the wheel hub and bearing mounting bolts to 90 Nm (66 ft. lbs.). 3. Install the brake rotor. 4. Install the tire and wheel. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 6150 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 39144 Composite Rotor Mounting Adapter - J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit - J 39544-KIT Complete Torque Socket Set (10 Pieces) Important: Do NOT refinish the brake rotors in order to correct any of the following complaints: ^ Brake noise (growl/squeal) ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the rotor braking surface ^ Rotor discoloration Refinish the brake rotors ONLY when one or more of the following conditions exist: ^ Severe scoring of the rotor braking surface (groove depth in excess of 1.5 mm (0.060 in) ^ Brake pulsation caused by the following: Brake rotor thickness variation in excess of 0.025 mm (0.001 in) - Corrosion or pitting of the rotor braking surface that is deeper than the rotor braking surface The following brake lathes are approved and achieve satisfactory results. ^ Accu Turn (off-vehicle) ^ Pro-Cut (on-vehicle) Notice: Do not allow the brake components to hang from the flexible brake hoses. Damage to the brake hoses could result. 1. Remove and support the brake caliper. 2. Make a mark on the brake rotor in order to identify the relationship to the hub. Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and brake pulsation. 3. Remove the brake rotor. 4. Use the J 42450-A in order to clean the wheel bearing/hub. 5. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the brake rotor. Replace the brake rotor. 6. Use the J41013 (or equivalent) in order to thoroughly clean the rust from the rotor/hub flange and from the rotor/wheel mating surfaces. 7. Install the brake rotor. ^ If you use the Accu Turn (off-vehicle) brake lathe, install the brake rotor to the brake lathe. If you are machining a composite rotor, use the J 39144. Refer to the brake lathe manufacturer's operating instructions. ^ If you use the Pro-Cut (on-vehicle) brake lathe, install the brake rotor to the vehicle. Align the brake rotor to the hub using the marks made during the removal procedure. 8. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible rotor finish may cause the vehicle to stop with difficulty. 9. After machining the rotor, use 120 grit aluminum oxide sandpaper and a non-directional rotor finisher (if available) in order to create a non-directional braking surface. 10. Clean the braking surfaces with denatured alcohol or with a suitable brake cleaner. 11. If you use the Accu Turn (off-vehicle) brake lathe, remove the brake rotor from the brake lathe and install the brake rotor to the vehicle. Align the brake rotor to the hub using the marks made during the removal procedure. 12. Install the brake caliper. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. 13. Use the applicable torque socket from the J 39544-KIT or a torque wrench in order to install the wheel to the correct specification. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Backing Plate Mounting Bolts 35 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 6155 Backing Plate: Service and Repair Brake Backing Plate Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the brake shoes. 5. Remove the wheel cylinder. 6. Remove the axle shaft. 7. Remove the backing plate bolts. 8. Remove the backing plate. Installation Procedure 1. Install the backing plate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the backing plate bolts. ^ Tighten the bolts to 48 Nm (35 ft. lbs.). 3. Install the axle shaft. 4. Install the wheel cylinder. 5. Install the brake shoes. 6. Install the brake drum. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Drum Discard Diameter* 9.59 in *All brake drums have a discard dimension cast into them. Replace any drum that does not meet this specification. After refinishing the drum, replace any drum that does not meet the maximum or discard diameter specifications. Drum Maximum Allowable Diameter After Refinish 9.56 in Inside Diameter (new) 9.50 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement Brake Drum Replacement Removal Procedure 1. Raise the vehicle and support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the tire and the wheel from the vehicle. 3. Mark the relationship of the rear brake drum to the axle for reference. 4. Remove the rear brake drum retainers if present. 5. Remove the rear brake drum from the vehicle. Installation Procedure 1. Locate the relationship mark and install the brake drum to the axle. 2. Install the tire and the wheel. 3. Adjust the rear brakes. 4. Remove the safety stands. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 6161 Brake Drum: Service and Repair Brake Drum Refinishing Brake Drum Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit Important: Do NOT refinish the brake drums in order to correct any of the following complaints: ^ Brake noise (growl/squeal) ^ Premature brake lining wear ^ Cosmetic or superficial corrosion of the drum braking surface ^ Drum discoloration Refinish the brake drums ONLY when one or more of the following conditions exist: ^ Severe scoring of the drum braking surface (groove depth in excess of specification) ^ Brake pulsation caused by the following: Brake drum out of round (runout in excess of specification) - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, do NOT refinish the brake drum. Replace the brake drum. 2. Use the J41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-directional braking surface. 5. Clean the braking surfaces with GM P/N 12377981 or equivalent brake parts cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Information not supplied by the manufacturer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6165 Brake Shoe: Adjustments Drum Brake Adjustment ^ Tools Required J 21177-A Drum to Brake Shoe Clearance Gauge The rear brakes must be adjusted manually after replacing the brake shoes. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the brake drum. 3. Using the J21177-A measure the inside diameter of the brake drum. 4. Position the J21177-A over the linings of the rear brake shoes. 5. Turn the star wheel on the adjusting screw until there is approximately 0.50 mm (0.020 in) clearance between the J21177-A and the shoe linings at their widest point. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6166 6. Using a punch and hammer, remove and discard the knockout plug in the backing plate (1) which is directly behind the star wheel adjuster. 7. Install the brake drum. 8. Tighten the adjusting screw until light drag is present when the drum is rotated. The brake lining drag should be equal at both drums. 9. Apply the brake pedal two times in order to center the brake shoes on the locating pins. 10. Check the drums again for light drag. Adjust as necessary. 11. Install an adjusting hole cover in the backing plate. 12. Lower the vehicle. 13. Check the park brake adjustment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6167 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Mark the relationship of the brake drum to the axle. 4. Remove the brake drum. 5. Remove the brake shoe return springs. 6. Remove the brake shoe guide. 7. Remove the hold down springs. 8. Remove the hold down pins. 9. Remove the actuator lever and the actuator lever pivot. 10. Remove the actuator lever and the lever pivot. 11. Remove the lever return spring. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6168 12. Remove the parking brake strut and the strut spring. 13. Remove the parking brake lever. 14. Remove the brake shoes. 15. Remove the adjusting screw assembly and the adjusting screw spring from the brake shoes. 16. Inspect all parts for discoloration due to heat or stress. Replace parts as needed. 17. Replace all worn parts. 18. Inspect the wheel cylinder for signs of leakage. If there are signs of leakage, overhaul or replace the wheel cylinder. 19. Inspect the brake drum for scoring and machining tolerance. Installation Procedure 1. Lubricate the brake shoe backing plate, the adjusting screw threads, socket and socket face with a thin coat of high temperature silicone lubricant. Important: Do not interchange the right and left adjusting screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6169 2. Install the adjusting screw assembly and the adjusting screw spring on the brake shoes. The coils of the adjusting screw spring must not touch the adjusting screw. 3. Install the brake shoes on the backing plate. 4. Install the parking brake lever. 5. Install the strut spring on the parking brake strut. 6. Install the parking brake strut. 7. Install the actuator lever and the lever pivot. 8. Install the actuator lever return spring. 9. Install the hold down pins. 10. Install the hold down springs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 6170 11. Install the brake shoe guide. 12. Install the brake shoe return springs. 13. Install the brake drum. Align the marks made during disassembly. 14. Install the tire and wheel assembly. 15. Adjust the brakes. 16. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6175 Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 13 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6176 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure 1. Remove the brake shoes. 2. Disconnect the brake pipe. 3. Remove the wheel cylinder bolts. 4. Remove the wheel cylinder. Installation Procedure 1. Install the wheel cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel cylinder bolts. ^ Tighten the wheel cylinder bolts to 18 Nm (13 ft. lbs.). 3. Connect the brake pipe to the wheel cylinder. ^ Tighten the brake pipe fitting to 17 Nm (13 ft. lbs.). 4. Install the brake shoes. 5. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Brake System Pressure Bleed Initial Pressure Adjustment Setting (Leak Testing the Hydraulic Brake System) 10 psi Pressure Bleed Procedure Setting 35 psi Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Two Person Procedure Important: ^ Use the 2-person bleed procedure under the following conditions: Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake Pressure Modulator Valve (BPMV). - Air is trapped in the valve body ^ Do not drive the vehicle until the brake pedal feels firm. ^ Do not reuse brake fluid that is used during bleeding. ^ Use the vacuum, the pressure and the gravity bleeding procedures only for base brake bleeding. 1. Raise the vehicle in order to access the system bleed screws. 2. Bleed the system at the right rear wheel first. 3. Install a clear hose on the bleed screw. 4. Immerse the opposite end of the hose into a container partially filled with clean DOT 3 brake fluid. 5. Open the bleed screw 1/2 to one full turn. 6. Slowly depress the brake pedal. While the pedal is depressed to its full extent, tighten the bleed screw. 7. Release the brake pedal and wait 10-15 seconds for the master cylinder pistons to return to the home position. 8. Repeat the previous steps for the remaining wheels. The brake fluid that is present at each bleed screw should be clean and free of air. 9. This procedure may use more than a pint of fluid per wheel. Check the master cylinder fluid level every four to six strokes of the brake pedal in order to avoid running the system dry. 10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure. Release the brake pedal between each test. 11. Bleed all four wheels again using Steps 3-9. This will remove the remaining air from the brake system. 12. Evaluate the feel of the brake pedal before attempting to drive the vehicle. 13. Bleed the system as many times as necessary in order to obtain the appropriate feel of the pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6183 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder; then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, when cap removal is necessary. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 6. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM PIN 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 7. Have an assistant slowly depress the brake pedal fully and maintain pedal position. 8. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 9. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 10. Wait 15 seconds, then repeat steps 7-9 until all air is purged from the same wheel hydraulic circuit. 11. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit; install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 12. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit; install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 13. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit; install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 6-10. 14. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 15. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 17. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 17.1. Inspect the brake system for external leaks. 17.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 18. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 19. If the brake system warning lamp remains illuminated, the hydraulic brake pressure differential switch plunger may have be forced out of position during the bleeding procedure and may need to be reset. Perform the following steps to reset the switch. 19.1. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6184 19.2. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 19.3. With the ignition key still ON, with the engine OFF, loosen the bleeder valve. 19.4. Have an assistant slowly depress the brake pedal until the brake system warning lamp turns OFF and maintain pedal position while you tighten the bleeder valve. 19.5. Have the assistant slowly release the brake pedal. 20. If the brake system warning lamp continues to remain illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6185 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 29567 Brake Pressure Bleeder Adapter - J 39177 Combination Valve Pressure Bleeding Tool, or equivalent - J 41618 Brake Bleeder Adapter Set Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Remove the cap from the metering valve end of the combination valve, then install the J 39177, or equivalent to the metering valve. 6. Using the J 39177, depress the shaft of the metering valve to maintain the proper flow of brake fluid to the front wheel hydraulic circuit during the pressure bleeding procedure. 7. Assemble the J41613 to the J29567. 8. Install the J41618 and J29567to the brake master cylinder reservoir. 9. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 10. Connect the J29532, or equivalent, to the J 29567. 11. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 12. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 13. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 14. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 15. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 16. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 17. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 18. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 15-16. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right front hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6186 valve, then repeat steps 15-16. 20. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 21. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 29567. 22. Remove the J 41618 and J29567 from the brake master cylinder reservoir. 23. Remove the J 39177, or equivalent from the metering valve, then install the cap to the metering valve end of the combination valve. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 28. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 6187 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the halfway point with Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Brake Caliper Bleeder Valve (Front) 115 inch lbs. Brake Caliper Bleeder Valve (Rear) 115 inch lbs. Caliper Mounting Bolts 38 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection Brake Caliper: Service and Repair Brake Caliper Inspection Brake Caliper Inspection 1. Inspect the brake caliper housing (1) for cracks, excessive wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper piston(s) into the caliper bore(s). The movement of the caliper piston(s) into the caliper bore(s) should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. ^ For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. ^ For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6193 Brake Caliper: Service and Repair Brake Caliper Overhaul Brake Caliper Overhaul ^ Tools Required J 26267 Piston Seal Installer Removal Procedure 1. Remove the caliper. 2. Drain all the brake fluid from the caliper. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding. 3. Pad the interior of the caliper with clean shop towels. 4. Remove the piston from the caliper bore. 5. Remove the boot from the caliper bore. Do not scratch the housing bore. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6194 6. Remove the piston seal from the caliper bore. Do not use a metal tool. 7. Remove the bleeder valve from the caliper body. 8. Clean the bleeder valve, the caliper bore, the caliper passages and the piston with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air. 9. Inspect the piston and the caliper for the following conditions: ^ Scoring on the piston surface or in the caliper bore ^ Corrosion on the piston ^ Chrome plating damage on the piston ^ Corrosion in the caliper bore Use crocus cloth in order to polish light corrosion from the caliper bore. Replace the caliper if the corrosion cannot be removed. ^ Pitting in the caliper bore 10. Replace the piston or the caliper if you found any of the above conditions. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6195 1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake fluid. 2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore groove. 3. Install the boot on the piston. 4. Install the piston in the caliper bore. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6196 5. Install the boot into the caliper housing bore using the J 26267. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bleeder valve in the caliper body. ^ Tighten the bleeder valve to 13 Nm (115 inch lbs.). Important: Before moving the vehicle, pump the brake pedal until it is firm. Check the brake fluid level in the master cylinder after pumping the brakes. 7. Install the caliper. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6197 Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and hand tighten a wheel lug nut in order to retain the rotor (A4WD only). 7. Compress the front caliper piston. ^ Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. ^ Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor. ^ Remove the C-clamp from the caliper. 8. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 9. Plug the opening in the front brake hose (2) in order to prevent excessive brake fluid loss and contamination. Do not pinch off the brake hose with any tools. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6198 10. Remove the caliper mounting bolts. 11. Remove the caliper. 12. Remove the brake pads. 13. Remove the bushings. 14. Remove the sleeves (RWD only). 15. Inspect the caliper bolts for corrosion or damage. Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper. Installation Procedure 1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent. 2. Dry the brake caliper pin bolts using non-lubricated, filtered air. 3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers. DO NOT apply lubricant to the brake pad hardware. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6199 4. Install the bushings. 5. Install the sleeves (RWD only). 6. Install the brake pads. 7. Install the caliper assembly. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the mounting bolts. ^ Tighten the bolts to 51 Nm (38 ft. lbs.). Important: Install NEW copper brake hose gaskets. 9. Install the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). 10. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 44 Nm (32 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Inspection > Page 6200 11. Remove the wheel lug nut securing the rotor to the hub. 12. Measure the clearance between the caliper and the steering knuckle. Measure the clearance at each end of the caliper individually and then add the measurements together. Specification The total should be 0.26 - 0.60 mm (0.010 - 0.024 in). ^ If the total clearance between the caliper and the steering knuckle is less than 0.26 mm (0.010 in), file the steering knuckle equally on each side until the proper clearance is obtained. ^ If the total clearance between the caliper and the steering knuckle is more than 0.60 mm (0.024 in), inspect the brake caliper and the steering knuckle for damage and replace as needed. 13. Install the tire and wheel. 14. Lower the vehicle. 15. Fill the master cylinder to the proper level with clean brake fluid. 16. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Type Delco Supreme 11 or equivalent DOT-3 brake fluid Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake Hose to Caliper Bolt 32 ft. lbs. Brake Pipes to Combination Valve Nuts 22 ft. lbs. Front Brake Pipe Nuts 22 ft. lbs. Front Brake Pipe to Hose Nuts 13 ft. lbs. Rear Brake Hose Junction Block to Rear Axle Bracket Bolt 13 ft. lbs. Rear Brake Pipe Nuts 13 ft. lbs. Brake Pipe Fittings 13 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement Brake Hose/Line: Service and Repair Brake Hose Replacement Front Brake Hose Replacement - Front (RWD) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Clean all dirt and foreign material from the brake hoses and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Use a backup wrench on the hose fitting (4), disconnect the brake pipe fitting (1) from the brake hose, then cap or plug the brake pipe fitting end. 4. Remove the brake hose retaining clip (2) from the hose mounting bracket. 5. Remove the hose (4) from the bracket. 6. Remove the brake hose to caliper bolt (5) from the brake caliper. 7. Remove the brake hose (4) from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets (6). These gaskets may be stuck to the brake caliper and/or the brake hose end. Installation Procedure Important: Install NEW copper brake hose gaskets (6). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement > Page 6209 1. Assemble the NEW copper brake hose gaskets (6), and the brake hose bolt (5) to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake hose to caliper bolt and NEW washers to the brake caliper. ^ Tighten the bolt to 44 Nm (32 ft. lbs.). Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component. 3. With the weight of the vehicle on the suspension, install the brake hose into the bracket. 4. Install the retainer (2) onto the hose fitting (4) at the bracket. 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting nut (1) to the brake hose (4): ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or the pipe. ^ Tighten the pipe nut to 17 Nm (13 ft. lbs.). 7. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 8. Bleed the hydraulic brake system. 9. Lower the vehicle. Rear Brake Hose Replacement- Rear Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement > Page 6210 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Clean all dirt and foreign material from the brake hoses and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Use a backup wrench on the hose fitting, disconnect the brake pipe fittings from the junction block, then cap or plug the brake pipe fitting ends. Do not bend the brake pipe or the bracket. 4. Disconnect the brake pipe fitting (9). 5. Remove the brake hose retaining clip (2). 6. Remove the junction block bolt (5). 7. Remove the rear brake hose (4). Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement > Page 6211 1. Install the rear brake hose (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolt (5). ^ Tighten the junction block bolt to 17 Nm (13 ft. lbs.). 3. Install the brake hose retaining clip (2). 4. Connect the brake pipe fitting (9). ^ Tighten the brake pipe fitting to 17 Nm (13 ft. lbs.). 5. Loosely connect the rear brake pipe fittings to the junction block. ^ Using a backup wrench, tighten the rear brake pipe fittings to 17 Nm (13 ft. lbs.). 6. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 7. Bleed the hydraulic brake system. 8. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Hose Replacement > Page 6212 Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Caution: Always use double-walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and in the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and brake system resulting in personal injury. Maintain a 6 mm (0.25 in) clearance between brake pipes that run parallel to each other. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Combination Valve Bolts 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 6216 Brake Proportioning/Combination Valve: Service and Repair Combination Valve Replacement Removal Procedure Important: Note the identification code on the combination valve. The new valve must have the same identification number as the old valve. 1. Remove the Master Cylinder. 2. Remove the combination valve electrical connector. 3. Remove the front and the rear brake pipes. 4. Remove the combination valve from the vehicle. Installation Procedure Important: Verify that the replacement combination valve has the same pin punched identification code as the code on the old combination valve. 1. Install the combination valve to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front and the rear brake pipes to the combination valve. ^ Tighten the brake pipe nuts to 30 Nm (22 ft. lbs.). 3. Connect the combination valve electrical connector. 4. Install the Master Cylinder. Important: Verify that the combination valve metering rod is depressed during bleeding. 5. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU (1) MUST be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the 2 electrical harness connectors from the EBCM. Important: Make sure that brake lines are tagged and kept in order for proper reassembly. 3. Disconnect 5 brake lines from the BPMV. 4. Slide the EHCU (1) off of the frame bracket (2). 5. Remove 2 bolts (4) securing the BPMV mounting bracket (3) to the BPMV (5). 6. Disconnect the 2-way ABS pump motor connector. 7. Remove the 4 T-25 Torx bolts (1) from the EBCM (2). Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 8. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not reuse the EBCM mounting bolts. Always install new bolts. 9. Clean the EBCM to BPMV mounting surfaces with a clean cloth. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Page 6220 Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. 1. Install EBCM (2) onto BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. Important: Do not reuse the old mounting bolts. Always install new bolts with the new BPMV. 2. Install the 4 EBCM bolts (1). ^ Tighten the 4 bolts to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the 2-way ABS pump motor connector to the EBCM. 4. Install the BPMV (5) to the BPMV mounting bracket (3) with the 2 bolts (4). 5. Slide the EHCU (1) back onto the frame bracket (2). Important: The brake pipes are held in the proper place by a frame mounted plastic bracket. Make sure that the brake pipes stay in the correct place for proper reassembly. 6. Install the 5 brake pipes to the EHCU (1). ^ Tighten the brake pipe fittings to 30 Nm (22 ft. lbs.). 7. Connect the 2 electrical harness connectors to the EBCM (1). 8. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the 2 nuts (4). 9. Bleed the brake system. 10. Return to Diagnostic System Check - ABS. See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Brake Pipe Nuts 22 ft. lbs. Master Cylinder to Booster Nuts 27 ft. lbs. Master Cylinder brake lines to BPMV 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6226 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6227 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder Replacement Removal Procedure Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Apply the parking brake and block the wheels. 2. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 3. Plug the open brake pipe ends. 4. Remove the master cylinder nuts and bolts. 5. Remove the combination valve bracket. 6. Remove the master cylinder from the vehicle. 7. Drain the master cylinder of all brake fluid. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6228 1. Bench bleed the master cylinder. 2. Install the master cylinder to the vehicle. 3. Install the combination valve bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the master cylinder bolts and nuts. ^ Tighten the nuts to 36 Nm (27 ft. lbs.). 5. Connect the brake pipes to the master cylinder. ^ Tighten the pipe nuts to 30 Nm (22 ft. lbs.). 6. Bleed the hydraulic brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6229 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Disassembly Procedure 1. Remove the master cylinder from the vehicle. 2. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 3. Carefully tap out the reservoir retaining pins. 4. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 5. Remove the seals from the master cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6230 Assembly Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11 (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals, make sure they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully tap the reservoir retaining pins into place to secure the reservoir. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6231 8. Install the diaphragm in the cover. 9. Install the cover on the reservoir. 10. Remove the master cylinder from the vice. 11. Install the master cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 6232 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11, GM P/N 12377967, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6237 Wheel Cylinder: Specifications Wheel Cylinder Mounting Bolts 13 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 6238 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Removal Procedure 1. Remove the brake shoes. 2. Disconnect the brake pipe. 3. Remove the wheel cylinder bolts. 4. Remove the wheel cylinder. Installation Procedure 1. Install the wheel cylinder. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel cylinder bolts. ^ Tighten the wheel cylinder bolts to 18 Nm (13 ft. lbs.). 3. Connect the brake pipe to the wheel cylinder. ^ Tighten the brake pipe fitting to 17 Nm (13 ft. lbs.). 4. Install the brake shoes. 5. Bleed the brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Cable Clip Bolts 71 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement Parking Brake Cable: Service and Repair Park Brake Cable Replacement Front Park Brake Cable Replacement- Front Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Loosen the park brake cable at the equalizer. 3. Remove the front park brake cable from the park brake cable connector. 4. Lower the vehicle. 5. Remove the front cable (1) from the lever assembly (2). 6. Remove the cowl side panel trim. 7. Remove the lever assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 6245 8. Remove the step trim plate. Lift the rocker panel trim and peel back the carpet to expose the park brake cable grommet (4). 9. Remove the front cable (3). Unclip the cable and pull through the body. Installation Procedure 1. Install the front cable. ^ Secure the grommet (4) to the body. ^ Clip the cable at the kick panel. 2. Connect the cable (1) to the lever assembly (2). 3. Install the lever assembly. 4. Install the cowl side panel. 5. Install the step trim plate. 6. Connect the front cable to the lever assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 6246 7. Raise the vehicle. Refer to Vehicle Lifting. 8. Connect the front cable to the park brake cable connector. 9. Adjust the park brake. 10. Lower the vehicle. Rear Park Brake Cable Replacement- Rear Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Loosen the equalizer. 3. Remove the rear cable from the equalizer. 4. Remove the brake drum and the shoe assembly. 5. Depress the cable-retaining fingers and remove the cable from the backing plate. 6. Remove the rear cable from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 6247 1. Install the rear cable into the backing plate. Ensure all retaining fingers are completely through the backing plate. 2. Install the brake shoes and the drum assembly. 3. Install the park brake cable to the equalizer. 4. Adjust the park brake. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement > Page 6248 Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Loosen the equalizer and remove the threaded rod. 3. Remove the front park brake cable from the connector. 4. Remove the left rear park brake cable from the equalizer. Installation Procedure 1. Install the left rear park brake cable to the equalizer. 2. Install the front park brake cable to the connector. 3. Install the threaded rod to the equalizer and install the nut to the rod. 4. Adjust the park brake. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Park Brake Release Handle Assembly Replacement Removal Procedure 1. Remove the release handle cable and grommet from the park brake pedal assembly (1). 2. Depress the locking tabs and remove the release handle (5) from the instrument panel. Installation Procedure 1. Install the release handle (5) to the instrument panel. Ensure the locking tabs secure the handle to the instrument panel. 2. Install the release handle grommet and cable to the park brake pedal assembly (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications Parking Brake Pedal: Specifications Park Brake Pedal Mounting Bolts 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 6255 Parking Brake Pedal: Service and Repair Park Brake Pedal Assembly Replacement Removal Procedure 1. Release the park brake (5). 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Loosen the equalizer. 4. Lower the vehicle. 5. Remove the release handle cable and grommet from the park brake pedal assembly. 6. Depress the locking tabs and remove the release handle from the instrument panel. 7. Disconnect the electrical connector from the park brake switch. 8. Remove the bolts (2). 9. Disconnect the park brake cable (3) from the lever (1). The locating tab on the lever must be straightened to release the cable. 10. Depress the locking tabs on the park brake cable housing and remove the cable housing from the pedal assembly. 11. Remove the lever assembly from the vehicle. Installation Procedure 1. Install the park brake cable housing to the park brake pedal assembly. Ensure that the locking tabs secure the housing to the assembly. 2. Connect the park brake cable (3) to the lever assembly. Bend the locating tab over the cable. 3. Install the lever assembly to the vehicle. Notice: Refer to fastener Notice in Service Precautions. 4. Install the bolts (2). ^ Tighten the bolts to 24 Nm (18 ft. lbs.). 5. Connect the connector to the park brake switch. 6. Install the release handle to the instrument panel. Ensure the locking tabs secure the handle to the instrument panel. 7. Install the release handle grommet and cable to the park brake pedal assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 6256 8. Adjust the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation Brake Lamp The BRAKE warning lamp on the instrument cluster turns on when the park brake is applied. The BRAKE lamp can also be turned on by the switch in the combination valve and the antilock brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 6260 Parking Brake Warning Lamp: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the park brake warning lamp switch electrical connector. 2. Remove the retainer from the switch. 3. Remove the park brake indicator switch (1) from the vehicle. Installation Procedure 1. Install the park brake indicator switch (1) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. ^ Tighten the retaining screw to 4 Nm (35 inch lbs.). 3. Install the park brake indicator switch electrical connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications Hydraulic Brake Booster: Specifications Hydraulic Brake Booster Hose Nuts 20 ft. lbs. Hydraulic Brake Booster Relief Valve 9 ft. lbs. Hydraulic Brake Booster to Engine Cowl Nuts 27 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications > Page 6265 Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Removal Procedure Notice: Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. 1. Apply the park brake. 2. Place a drain pan under the hydraulic brake booster and the booster reservoir. 3. Disconnect the reservoir hose from the booster. 4. Disconnect the power steering hoses from the booster. Important: Do not remove the brake pipes from the master cylinder. 5. Remove the master cylinder nuts. 6. Support the master cylinder. 7. Disconnect the pushrod from the brake pedal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications > Page 6266 8. Remove the hydraulic booster mounting nuts from the inside of the vehicle. 9. Remove the booster assembly. 10. Remove the gasket. Installation Procedure 1. Install the gasket. 2. Install the booster assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the booster mounting nuts. ^ Tighten the nuts to 36 Nm (27 ft. lbs.). 4. Connect the pushrod to the brake pedal. 5. Install the master cylinder. 6. Install the master cylinder nuts. ^ Tighten the nuts to 36 Nm (27 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Specifications > Page 6267 7. Connect the power steering hoses to the booster. ^ Tighten the hose fittings to 27 Nm (20 ft. lbs.). 8. Connect the reservoir hose to the booster. 9. Bleed the hydraulic brake booster. 10. Release the parking brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement ^ Tools Required J 26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Depress brake pedal at least twenty times to relieve pressure in the accumulator. 2. Remove the master cylinder nuts from the hydraulic booster. 3. Remove the master cylinder and secure away from the hydraulic booster. 4. Remove the hydraulic booster. 5. Place the J 26689 over the end of the accumulator. 6. Install the nut on the stud. 7. Depress the accumulator with a C-clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 6271 8. Rotate retaining ring (2) until either end of the ring is under the access hole (1). 9. Depress and hold the ring with a small tool inserted into the access hole 10. Remove the accumulator retainer ring (1) using a small hook shaped tool. 11. Release the C-clamp. 12. Remove the nut from the stud. 13. Remove the J26889. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 6272 14. Remove the accumulator (2) and O-ring seal (3). Installation Procedure 1. Lubricate all seals and metal friction points with power steering fluid. 2. Install the accumulator (2) and O-ring seal (3). 3. Place the J 26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair > Page 6273 6. Install the accumulator retainer ring (2). 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J 26889. 10. Install the hydraulic booster. 11. Install the master cylinder to the hydraulic brake booster. Notice: Refer to Fastener Notice in Service Precautions. 12. Install the master cylinder nuts. ^ Tighten the master cylinder nuts to 36 Nm (27 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Customer Interest for Vacuum Brake Booster: > 02-02-32-005A > Apr > 02 > Power Steering - Whining Noise While Turning Vacuum Brake Booster: Customer Interest Power Steering - Whining Noise While Turning File in section: 02 - Steering Bulletin No.: 02-02-32-005A Date: April, 2002 TECHNICAL Subject: Excessive Noise from Power Steering System While Turning or Under Light Braking (Replace Power Brake Booster Inlet Hose) Models: 1999-2002 Chevrolet and GMC M/L-Van Models This bulletin is being revised to change the model years. Please discard Corporate Bulletin Number 02-02-32-005 (Section 02 - Steering). Condition Some customers may comment on a whine noise coming from the power steering system while turning or braking. Correction Replace the power brake booster inlet hose, P/N 15094588. Follow the service procedure listed below. 1. Remove the power brake booster inlet hose from the pump to the hydraulic booster and discard the hose. Refer to the Power Brake Booster Inlet Hose Replacement procedure in the Service Manual (SI ID # 546584). Important: Routing of the power brake booster inlet hose (1) at the hydraulic brake booster is critical for proper installation. 2. Install and route the inlet brake booster hose (1) from the hydraulic brake booster to the rear of the outlet brake booster hose (2) and under the brake lines (3) and down to the rear of the pump. Tighten Tighten the power brake booster inlet hose fittings to 27 N.m (20 lb ft). 3. Bleed the power steering system. Refer to the Bleeding the Power Steering System procedure in the Service Manual (SI ID # 487449). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Customer Interest for Vacuum Brake Booster: > 02-02-32-005A > Apr > 02 > Power Steering - Whining Noise While Turning > Page 6282 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 02-02-32-005A > Apr > 02 > Power Steering - Whining Noise While Turning Vacuum Brake Booster: All Technical Service Bulletins Power Steering - Whining Noise While Turning File in section: 02 - Steering Bulletin No.: 02-02-32-005A Date: April, 2002 TECHNICAL Subject: Excessive Noise from Power Steering System While Turning or Under Light Braking (Replace Power Brake Booster Inlet Hose) Models: 1999-2002 Chevrolet and GMC M/L-Van Models This bulletin is being revised to change the model years. Please discard Corporate Bulletin Number 02-02-32-005 (Section 02 - Steering). Condition Some customers may comment on a whine noise coming from the power steering system while turning or braking. Correction Replace the power brake booster inlet hose, P/N 15094588. Follow the service procedure listed below. 1. Remove the power brake booster inlet hose from the pump to the hydraulic booster and discard the hose. Refer to the Power Brake Booster Inlet Hose Replacement procedure in the Service Manual (SI ID # 546584). Important: Routing of the power brake booster inlet hose (1) at the hydraulic brake booster is critical for proper installation. 2. Install and route the inlet brake booster hose (1) from the hydraulic brake booster to the rear of the outlet brake booster hose (2) and under the brake lines (3) and down to the rear of the pump. Tighten Tighten the power brake booster inlet hose fittings to 27 N.m (20 lb ft). 3. Bleed the power steering system. Refer to the Bleeding the Power Steering System procedure in the Service Manual (SI ID # 487449). Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 02-02-32-005A > Apr > 02 > Power Steering - Whining Noise While Turning > Page 6288 For vehicles repaired under warranty, use the table shown. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Brake Pressure Modulator Bleeder Valves 80 inch lbs. EBCM to BPMV 39 inch lbs. Front Brake Lines to BPMV 18 ft. lbs. Rear Brake Line to BPMV 18 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6293 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6294 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (EBCM) C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6295 Electronic Brake Control Module (EBCM) C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6296 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Important: After installation, calibrate the new EBCM to the tire size that is appropriate to the vehicle. 1. Remove the fuel pipe shield (3) from the frame bracket (2) by removing the 2 nuts (4). Important: Thoroughly wash all contaminants from around the EHCU (1). The area around the EHCU must be free from loose dirt to prevent contamination of disassembled ABS components. 2. Disconnect the electrical connectors from the EBCM. 3. Remove the 4 T-25 Tort mounting screws (1) that fasten the EBCM (2) to the BPMV (5). 4. Remove the EBCM (2) from the BPMV (5). Removal may require a light amount of force. Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force will damage the EBCM. 5. Clean the BPMV to EBCM mounting surfaces with a clean cloth. Installation Procedure Important: Do not reuse the old mounting screws (1). Always install new mounting screws with the new EBCM. Important: Do not use RTV or any other type of sealant on the EBCM gasket or mating surfaces. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6297 1. Install EBCM (2) on to the BPMV (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the 4 new T-25 Torx screws (1) in the EBCM (2). ^ Tighten the 4 T-25 Torx screws to 5 Nm (39 inch lbs.) in an X-pattern. 3. Connect the electrical connectors to the EBCM. 4. Secure the module (1) to the frame bracket (3) and fuel pipe shield (2) with the two nuts (4). 5. Revise the tire calibration using the Scan Tool Tire Size Calibration function. 6. Return to Diagnostic System Check - ABS on. See: Antilock Brakes / Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: Customer Interest Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 6307 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation Wheel Speed Sensor: All Technical Service Bulletins Brakes - Low Speed (Below 5 MPH) ABS Activation Bulletin No.: 02-05-25-006B Date: January 05, 2006 TECHNICAL Subject: Antilock Brake (ABS) Activation At Low Speeds (Clean Wheel Speed Sensor Mounting Surface) Models: 1999-2000 Cadillac Escalade 1995-1999 Chevrolet Silverado (Old Style) 1995-2000 Chevrolet Suburban, Tahoe (Old Style) 1995-2003 Chevrolet Astro Van, Blazer, S10 1995-1999 GMC Sierra (Old Style) 1995-2000 GMC Yukon, Yukon XL (Old Style) 1995-2001 GMC Envoy, Jimmy 1995-2003 GMC Safari Van, Sonoma 1995-2001 Oldsmobile Bravada Supercede: This bulletin is being revised to update the correction and warranty information. Please discard Corporate Bulletin Number 02-05-25-006A (Section 05 - Brakes). Condition Some customers may comment on ABS activation at low speeds, usually below 8 km/h (5 mph). Upon investigation, the technician will find no DTCs set. Cause The cause of this condition may be an increased air gap between the wheel speed sensor and the hub reluctor ring due to rust and debris built up on the sensor mounting surface. Correction Measure AC voltage and clean wheel speed sensor mounting surfaces. 1. Raise the vehicle on a hoist. 2. Disconnect both the front wheel speed sensor harness connectors. 3. Place a DVM across the terminals of each sensor connector. 4. Rotate the wheel with hand speed and measure the ACmV's. The reading should be at least 350 ACmV's. 5. If the reading is between 200 and 350 ACmV's, remove the wheel, caliper and rotor in order to gain access to the speed sensor. 6. Remove the wheel speed sensor and plug the hole to prevent debris from falling into the hub during service. 7. Clean the wheel speed sensor mounting surface using a wire brush, sand paper, emery cloth, ScotchBrite(TM) or other suitable material. Be sure to thoroughly clean the wheel speed sensor surface. There should be no rust or corrosion. 8. Check the sensor head to determine if it has been warped/distorted due to the corrosion build up or other causes. Check the mounting surface on the sensor head for flatness by placing it on the edge of a metal machinists scale or other suitable straight edge to measure the flatness. Check the sensor for flatness in multiple (minimum 3) positions/directions. If the sensor head is distorted, replace the sensor. 9. Apply (spray) two thin coats of the specified rust penetrating lubricant (corrosion inhibitor) to the complete sensor mounting surface on the bearing hub. Allow to dry for 3-5 minutes between coats. Use ONLY Rust Penetrating Lubricant, P/N 89022217 (Canadian P/N 89022218). 10. When the corrosion inhibitor is dry to the touch (about 10 minutes), apply a thin layer of bearing grease to the hub surface and sensor 0-ring prior to sensor installation. Use ONLY Wheel Bearing Lubricant, P/N 01051344 (Canadian P/N 993037). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 02-05-25-006B > Jan > 06 > Brakes - Low Speed (Below 5 MPH) ABS Activation > Page 6313 11. Install either the original sensor or a new one in the hub and secure the sensor. Ensure that the sensor is seated flush against the hub. 12. Install the rotor, the caliper and the wheel. 13. Place the DVM across the sensor terminals and recheck the voltage while rotating the wheel by hand. The voltage should now read at least 350 ACmV's. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6314 Wheel Speed Sensor: Specifications Front Wheel Speed Sensor Mounting Bolt 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6315 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6316 Wheel Speed Sensor: Diagrams Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6317 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement (RWD) Removal Procedure 1. Raise the vehicle. 2. Remove the tire and wheel. 3. Remove the brake caliper (1). 4. Remove the hub and rotor assembly (3). 5. Remove the wheel speed sensor cable electrical connector (2). 6. Remove the wheel speed sensor harness clip rivets using a 3/16 inch drill bit. 7. Remove the clips from the wheel speed sensor wire. Save the clips for the replacement sensor. 8. Remove the wheel speed sensor mounting bolts and nut. 9. Remove the 2 splash shield mounting bolts (7). 10. Remove the wheel speed sensor and the splash shield assembly (6). 11. Remove the splash shield gasket. 12. Clean the gasket and knuckle (8) surfaces thoroughly with a dry cloth. Installation Procedure 1. Install the splash shield gasket. 2. Install the wheel speed sensor splash shield (6). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 11 mm splash shield mounting bolts. ^ Tighten the splash shield mounting bolts to 16 Nm (12 ft. lbs.). 4. Install the wheel speed sensor mounting bolts and nut. ^ Tighten the speed sensor mounting bolts to 26 Nm (19 ft. lbs.). 5. Install the harness clips to the wheel speed sensor wire. Locate the clips at the paint dots on the wire. 6. Install the harness clips with 3/16 inch rivets. 7. Connect the wheel speed sensor electrical connector (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6318 8. Install the hub and rotor (3). 9. Install the brake caliper (1). 10. Install the tire and wheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: ^ Always shield your eyes. ^ Avoid leaning over the battery whenever possible. ^ Do not expose the battery to open flames or sparks. ^ Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 6334 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: ^ Always shield your eyes. ^ Avoid leaning over the battery whenever possible. ^ Do not expose the battery to open flames or sparks. ^ Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you are unsure of the other vehicle's positive voltage or ground position. The booster battery and the discharged battery should be treated carefully when using jumper cables. 1. Position the vehicle with the booster battery so that the jumper cables will comfortably reach the battery of the other vehicle. ^ Do not let the 2 vehicles touch. ^ Make sure that the jumper cables do not have loose clamps or missing insulation. 2. Perform the following steps on both vehicles: 2.1. Place the automatic transmission in PARK. 2.2. Block the wheels. 2.3. Set the parking brake. 2.4. Turn off all electrical loads that are not needed. Leave the hazard flashers ON. 2.5. Turn OFF the ignition switch. IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the battery remote positive stud in order to give or to receive a jump start. 3. Attach the end of one jumper cable to the positive terminal of the discharged battery. 4. Attach the other end of the first cable to the positive terminal of the booster battery. 5. Attach one end of the remaining jumper cable to the negative terminal of the booster battery. NOTE: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment. 6. Make the final connection of the negative jumper cable to the block or suitable bracket connected directly to the block, away from the battery. 7. Start the engine of the vehicle that is providing the jump start and turn off all electrical accessories. Raise the engine RPM to approximately 1,500 RPM. 8. Crank the engine of the vehicle with the weak battery. If the engine does not crank or cranks too slowly, perform the following steps: 8.1. Turn the ignition OFF. 8.2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. 8.3. Attempt to start the engine of the vehicle with the discharged battery. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 6335 9. Reverse the steps exactly when removing the jumper cables. The negative battery cable must first be disconnected from the engine that was jump started. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service Precautions Negative: Service Precautions CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Remove the battery ground (negative) cable and bolt from the battery 4.3L. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. Install the battery ground (negative) cable and bolt to the battery. Tighten Tighten the battery terminal bolt to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 6342 Negative: Service and Repair Battery Negative Cable Replacement TOOLS REQUIRED J 39200 Digital Multimeter Excessive resistance caused by poor terminal connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent the normal starter operation and cause hard starting. Whenever the battery cables are replaced, use a replacement cable that is the same in the type, the diameter, and the length. Some positive cables have additional feed wires attached to them and some of the negative cables have additional ground leads attached. Inspection Procedure CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the battery feed at the distributor. 1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame. Place one probe of the J 39200 on the grounded battery post (not on the cable clamp) and the other on the frame. Operate the starter and note the voltage reading. 2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating. 3. Check the voltage drop between the starter housing and the frame with the starter operating. 4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit. In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned. If the cables are frayed or the clamps are corroded, the cables should be replaced. When selecting the new cables, ensure that the new cables are the same length and the same diameter as the original cables being replaced. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable bolt from the battery. 2. Disconnect the battery negative cable from the engine. 3. Disconnect any additional ground leads attached to the battery negative cable. 4. Remove the battery negative cable. Installation Procedure 1. For RWD, install the battery negative cable in the same position as the original. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 6343 2. For A4WD, install the battery negative cable in the same position as the original. NOTE: Refer to Fastener Notice in Service Precautions. 3. Connect the battery negative cable to the engine. Tighten Tighten the nut to 40 N.m (29 lb ft). 4. Install the engine harness to the stud. Tighten Tighten the nut to 25 N.m (18 lb ft). 5. Connect the battery negative cable ground lead to the radiator support. Tighten Tighten the stud to 45 N.m (33 lb ft). 6. Connect the battery negative terminal bolt to the battery. Tighten Tighten the bolt to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions Positive: Service Precautions CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the binary feed at the distributor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 6347 Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT TOOLS REQUIRED J 39200 Digital Multimeter Excessive resistance caused by poor terminal connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent the normal starter operation and cause hard starting. Whenever the battery cables are replaced, use a replacement cable that is the same in the type, the diameter, and the length. Some positive cables have additional feed wires attached to them and some of the negative cables have additional ground leads attached. Inspection Procedure CAUTION: In order to prevent possible personal injury from a moving vehicle or from an operating engine, perform the following steps before performing the checks: 1. Place the transmission in park. 2. Engage the parking brakes and block the wheels. 3. Disconnect the binary feed at the distributor. 1. Check the voltage drop between the ground (the battery negative terminal) and the vehicle frame. Place one probe of the J 39200 on the grounded battery post (not on the cable clamp) and the other on the frame. Operate the starter and note the voltage reading. 2. Check the voltage drop between the battery positive terminal and the starter terminal stud with the starter operating. 3. Check the voltage drop between the starter housing and the frame with the starter operating. 4. If the voltage drop in any of the above is more than 0.5 volts, there is excessive resistance in the circuit. In order to eliminate resistance, the cables should be disconnected and the connections should be cleaned. If the cables are frayed or the clamps are corroded, the cables should be replaced. When selecting the new cables, ensure that the new cables are the same length and the same diameter as the original cables being replaced. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery positive cable bolt from the battery. 2. Disconnect the battery positive cable from the starter motor. 3. Disconnect the additional battery positive cable lead to the electrical convenience center. 4. Remove the battery positive cable. Installation Procedure 1. For RWD, install the battery positive cable in the same position as the original. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service Precautions > Page 6348 2. For A4WD, install the battery positive cable in the same position as the original. NOTE: ^ When installing the positive battery cable to the starter solenoid, the inner nut on the solenoid battery terminal must be tightened before the battery cable and the other leads are installed. Failure to do so will result in the solenoid or the solenoid terminal damage. ^ Refer to Fastener Notice in Service Precautions. 3. Connect the battery positive cable to the starter solenoid. Tighten Tighten the nut to 9 N.m (80 lb in). 4. Connect the additional battery positive cable lead to the underhood electrical center. Tighten Tighten the nut to 9 N.m (80 lb in). 5. Connect the battery positive terminal bolt to the battery. Tighten Tighten the bolt to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage Generator Usage Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Amperage > Page 6354 Alternator: Specifications Voltage Voltage Charging Voltage 13-16 Volts Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6355 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Alternator: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 Generator Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6390 Alternator: Description and Operation GENERATOR The AD-230 generator is non-repairable. They are electrically similar to earlier models. The generator(s) feature the following major components: ^ The delta stator ^ The rectifier bridge ^ The rotor with slip rings and brushes ^ A conventional pulley ^ Dual internal fans ^ A voltage regulator The pulley and the fan cool the slip ring and the frame. The AD stands for Air-Cooled Dual internal fan; the 2 is an electrical design designator; the 30 denotes the outside diameter of the stator laminations in millimeters, over 100 millimeters. The generator is rated at 105 amperes. The generator features permanently lubricated bearings. Service should only include the tightening of mounting components. Otherwise, the generator is replaced as a complete unit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6391 Alternator: Service and Repair GENERATOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the air cleaner assembly. 3. Remove the drive belt. 4. Disconnect the regulator electrical connector. 5. Remove the generator front mounting bolts. 6. Remove the generator rear mounting bolt. 7. Remove the generator output (BAT) terminal nut. 8. Remove the generator. INSTALLATION PROCEDURE 1. Position the generator on the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Loosely install the mounting bolts. 3. Install the generator output (BAT) lead. 4. Loosely install the generator output (BAT) nut. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6392 ^ Tighten the mounting bolts to 50 N.m (37 lb ft). ^ Tighten the generator output (BAT) terminal nut to 20 N.m (15 lb ft). 5. Connect the regulator electrical connector. 6. Install the drive belt. 7. Install the air cleaner. 8. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Locations Ignition Lock: Locations For additional steering column components locations, Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Ignition Lock Cylinder - Revised Replacement Procedure Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition Lock Cylinder - Revised Replacement Procedure File In Section: 02 - Steering Bulletin No.: 02-02-35-001 Date: January, 2002 SERVICE MANUAL UPDATE Subject: Revised Ignition Lock Cylinder Replacement Models: 1998-2002 Chevrolet and GMC C/K, S/T, M/L and G Model Vehicles 1999-2000 Cadillac Escalade 2002 Cadillac Escalade 1998-2002 Oldsmobile Bravada This bulletin is being issued to revise the Ignition Lock Cylinder Replacement procedure in the Steering Wheel and Column - Standard or Steering Wheel and Column - Tilt sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The above mentioned Service Manuals omitted information regarding performing the Passlock Relearn or Autolearn procedure after an ignition lock cylinder has been replaced. If you have replaced the ignition lock cylinder, refer to the following procedures: For 1998-2000 model year vehicles, refer to Passlock Reprogramming in the Theft Deterrent subsection. For 2001-2002 model year vehicles, refer to Programming Theft Deterrent System Components in the Theft Deterrent subsection. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6406 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6407 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 6408 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Starter Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 6445 Starter Motor: Service and Repair STARTER MOTOR REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the starter motor mounting bolts. 4. Remove any shims previously used. 5. Lower the starter motor. 6. Disconnect the starter enable relay lead (1), the battery positive cable (2), and the generator output (BAT) lead (3) from the starter solenoid field leads. 7. Remove the starter motor. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Caution and Notices. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 6446 1. Connect the starter motor field leads to the starter motor as follows: 1.1. Loosely install the starter enable relay lead (1) to the starter solenoid terminal. Align the terminal retaining tab to the starter solenoid. 1.2. Loosely install generator output (BAT) lead (3) and the battery positive cable (2) to the solenoid terminal. Align the battery positive cable terminal retaining tab to the starter solenoid. Tighten ^ Tighten the starter enable relay lead nut to 2 N.m (18 lb in). ^ Tighten the battery positive cable nut to 19 N.m (14 lb ft). 2. Install the two starter motor mounting bolts and the shims (if necessary) through the starter to the engine. Tighten Tighten the bolts to 43 N.m (32 lb ft). 3. Lower the vehicle. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Locations Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 6457 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet - Front No. 1 Auxiliary Power Outlet - Rear Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 6458 Auxiliary Power Outlet - Front No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P > Page 6465 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6468 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6469 Fuse: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6470 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6471 Fuse: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6472 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6473 Fuse: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6474 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block > Page 6479 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6480 Fuse Block: Diagrams Convenience Center C1 Convenience Center C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6481 Convenience Center C4 Convenience Center C5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6482 Convenience Center C6 Convenience Center C8 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6483 Convenience Center C9 Convenience Center C10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) Fuse Block: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6486 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6487 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6488 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6489 Fuse Block: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6490 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6491 Fuse Block: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6492 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Fuse Block: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. IMPORTANT: ^ Always note the orientation of the relay. ^ Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 6495 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 6496 Fuse Block: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any Connector Position Assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any Connector Position Assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT Additional ground straps are used to connect the body frame to the engine and the transmission. Always connect all ground straps to ensure a good ground path to the battery for all electrical components. Removal Procedure 1. Remove the bolt. 2. Clean the bolt and the mounting surface. Installation Procedure 1. Install the ground lead. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt. Tighten Tighten the bolt to 40 N.m (29 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6504 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6505 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6506 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6507 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6508 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6509 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 Multiple Junction Connector: Diagrams C100 - C110 C104 (Engine To Forward Lamp) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6514 C100 (Engine To I/P) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6515 C100 (Engine To I/P) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6516 C102 (I/P To Forward Lamp) C108 (I/P to Rear Lamp Jumper VE1 Japan) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6517 C108 (I/P To Rear Lamp Jumper VE1 Japan) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID C109 (I/P to Forward Lamp) C109 (I/P To Forward Lamp) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6518 C110 (Engine To Brake Pressure Differential Switch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6519 Multiple Junction Connector: Diagrams C200 - C223 C200 (I/P to Main Body) C200 (I/P To Main Body) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6520 C201 (Steering Column to I/P) C201 (Steering Column To I/P) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6521 C201 (Steering Column To I/P) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6522 C201 (Steering Column To I/P) Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6523 C202 (I/P To Cig/Aux Power Jumper) C203 (I/P to Liftgate) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6524 C203 (I/P To Liftgate) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6525 C205 (I/P To Right/Passenger Door) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6526 C212 (Heater Jumper To Heater Body) C212 (Heater Jumper To Heater Body) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6527 C223 (Upfitter Harness) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6528 Multiple Junction Connector: Diagrams C300 - C333 C300 (I/P To Main Body) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6529 C301 (I/P To Left/Driver Door) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6530 C302 (Body To Overhead Console) C303 (Body To Overhead Console) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6531 C306 (Power Seat Supply Voltage To LH Power Seat) C308 (Transfer Case Harness To Transfer Case Extension Jumper) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6532 C309 (Transfer Case Harness To Transfer Case Extension Jumper) C310 (Engine To Fuel Pump Jumper) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6533 C314 (Engine To Wheel Speed Sensor Jumper) C333 (Upfitter Harness) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6534 Multiple Junction Connector: Diagrams C401 - C404 C401 (Main Body To Rear Door Jamb Switch) C403 (Rear Lamp Jumper to Rear Lamp Assembly Export W/WX7) C403 (Rear Lamp Jumper To Rear Lamp Assembly Export W/WX7) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6535 C404 (Main Body To Rear - Dome Lamp) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6541 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6542 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6545 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6546 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6547 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6548 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6549 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6554 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6555 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6558 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6559 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6560 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6561 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6562 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6571 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6572 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6573 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6579 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6580 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6581 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6586 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6587 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6588 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6589 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6590 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6591 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6596 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6602 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6603 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6604 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6605 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6606 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6607 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6612 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 6617 Auxiliary Power Outlet: Diagrams Auxiliary Power Outlet - Front No. 1 Auxiliary Power Outlet - Rear Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 6618 Auxiliary Power Outlet - Front No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P > Page 6625 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) Fuse: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6628 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6629 Fuse: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6630 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6631 Fuse: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6632 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6633 Fuse: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block I/P (Front View) > Page 6634 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Instrument Panel (I/P) Fuse Block > Page 6639 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6640 Fuse Block: Diagrams Convenience Center C1 Convenience Center C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6641 Convenience Center C4 Convenience Center C5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6642 Convenience Center C6 Convenience Center C8 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 6643 Convenience Center C9 Convenience Center C10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) Fuse Block: Application and ID Fuse Block - Underhood (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6646 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6647 Fuse Block: Application and ID Fuse Block - Underhood (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6648 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6649 Fuse Block: Application and ID Fuse Block I/P (Front View) Fuse Block I/P (Front View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6650 Fuse Block I/P (Front View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6651 Fuse Block: Application and ID Fuse Block I/P (Rear View) Fuse Block - I/P (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - Underhood (Front View) > Page 6652 Fuse Block - I/P (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) Fuse Block: Service and Repair Relay Replacement (Within an Electrical Center) TOOLS REQUIRED J 43244 Relay Puller Pliers REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Locate the relay. IMPORTANT: ^ Always note the orientation of the relay. ^ Make sure the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). NOTE: Use J 43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 6655 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Relay Replacement (Within an Electrical Center) > Page 6656 Fuse Block: Service and Repair Relay Replacement (Attached to Wire Harness) REMOVAL PROCEDURE 1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any Connector Position Assurance (CPA) devices or secondary locks. IMPORTANT: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). INSTALLATION PROCEDURE 1. Connect the relay (1) to the wire harness connector (2). 2. Install any Connector Position Assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Service and Repair Ground Strap: Service and Repair GROUND STRAP REPLACEMENT Additional ground straps are used to connect the body frame to the engine and the transmission. Always connect all ground straps to ensure a good ground path to the battery for all electrical components. Removal Procedure 1. Remove the bolt. 2. Clean the bolt and the mounting surface. Installation Procedure 1. Install the ground lead. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt. Tighten Tighten the bolt to 40 N.m (29 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6664 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6665 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6666 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6667 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6668 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6669 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 Multiple Junction Connector: Diagrams C100 - C110 C104 (Engine To Forward Lamp) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6674 C100 (Engine To I/P) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6675 C100 (Engine To I/P) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6676 C102 (I/P To Forward Lamp) C108 (I/P to Rear Lamp Jumper VE1 Japan) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6677 C108 (I/P To Rear Lamp Jumper VE1 Japan) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID C109 (I/P to Forward Lamp) C109 (I/P To Forward Lamp) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6678 C110 (Engine To Brake Pressure Differential Switch) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6679 Multiple Junction Connector: Diagrams C200 - C223 C200 (I/P to Main Body) C200 (I/P To Main Body) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6680 C201 (Steering Column to I/P) C201 (Steering Column To I/P) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6681 C201 (Steering Column To I/P) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6682 C201 (Steering Column To I/P) Part 3 For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6683 C202 (I/P To Cig/Aux Power Jumper) C203 (I/P to Liftgate) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6684 C203 (I/P To Liftgate) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6685 C205 (I/P To Right/Passenger Door) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6686 C212 (Heater Jumper To Heater Body) C212 (Heater Jumper To Heater Body) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6687 C223 (Upfitter Harness) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6688 Multiple Junction Connector: Diagrams C300 - C333 C300 (I/P To Main Body) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6689 C301 (I/P To Left/Driver Door) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6690 C302 (Body To Overhead Console) C303 (Body To Overhead Console) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6691 C306 (Power Seat Supply Voltage To LH Power Seat) C308 (Transfer Case Harness To Transfer Case Extension Jumper) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6692 C309 (Transfer Case Harness To Transfer Case Extension Jumper) C310 (Engine To Fuel Pump Jumper) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6693 C314 (Engine To Wheel Speed Sensor Jumper) C333 (Upfitter Harness) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6694 Multiple Junction Connector: Diagrams C401 - C404 C401 (Main Body To Rear Door Jamb Switch) C403 (Rear Lamp Jumper to Rear Lamp Assembly Export W/WX7) C403 (Rear Lamp Jumper To Rear Lamp Assembly Export W/WX7) For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C110 > Page 6695 C404 (Main Body To Rear - Dome Lamp) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6701 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6702 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6705 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6706 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6707 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6708 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6709 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 Relay Box: Locations Relay Block #1 Relay Block # 1 Under left side of dash on data link connector bracket facing rear of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6714 Relay Box: Locations Relay Block #2 Relay Block # 2 Under left side of dash on data link connector bracket facing front of vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Relay Block #1 > Page 6715 Fuse Block - Underhood Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 Relay Block No. 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6718 Relay Block No. 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6719 Relay Box: Application and ID Underhood Fuse-Relay Center (Front View) Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6720 Underhood Fuse Block (Front View) Part 2 Of 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6721 Relay Box: Application and ID Underhood Fuse-Relay Center (Rear View) Fuse Block - Underhood (Rear View) Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay Block #1 > Page 6722 Fuse Block - Underhood (Rear View) Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6731 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6732 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6733 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6739 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6740 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6741 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6746 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6747 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6748 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6749 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6750 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6751 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6756 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6762 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6763 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6764 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6765 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6766 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6767 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6772 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6778 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6779 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6780 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6781 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6782 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6783 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6784 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications Alignment: Specifications Camber Service Allowed -0.40 to + 1.60 Service Preferred 0.6 Cross Camber (L-R) Service Allowed -0.5 to +0.5 Service Preferred 0 Caster-Left Wheel Service Allowed 2.0 to 4.0 Service Preferred 3.0 Caster-Right Wheel Service Allowed 2.50 to 4.50 Service Preferred 3.5 Cross Caster (L-R) Service Allowed -1 to 0 Service Preferred -0.5 Steering Wheel Angle Service Allowed -6.0 to +4.0 Service Preferred -1.0 Toe (Total) Service Allowed 0.20 to 0.20 Service Preferred 0 Z Trim Height Service Allowed 2.86 to 3.34 in Service Preferred 3.10 in D Trim Height Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Specifications > Page 6787 Alignment: Specifications Z Trim Height RWD Service Allowed 2.86 to 3.34 in Service Preferred 3.10 in AWD Service Allowed 5.16 to 5.64 in Service Preferred 5.40 in D Trim Height ALL Service Allowed 5.31 to 5.71 in Service Preferred 5.50 in Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6788 Alignment: Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear and is not adjustable on this vehicle. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6789 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6790 causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 inch) to be considered correct. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use an adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 inch). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from the pivot bolt center line (3) down to the lower corner (5) of the lower ball joint (1) in order to obtain the Z height measurement (4). 5. Push the front bumper of the vehicle down about 38 mm (1.5 inch). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. Z Height Adjustment Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6793 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut, increases the Z height by approximately 6.0 mm (0.2 inch). 2. For vehicles without torsion bars replace damaged or worn components as necessary. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 inch). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 inch). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: - Sagging front suspension. - Worn rear suspension components, such as leaf spring bushings. - Improper tire inflation. - Improper weight distribution. - Collision damage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6794 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6795 Alignment: Service and Repair Front Wheel Alignment Front Caster and Camber Adjustment Front Caster and Camber Adjustment The caster and the camber adjustments are made by inserting shims between the upper control arm shaft and the frame bracket. The shims may be added, subtracted, or transferred in order to change the readings. Important: Before adjusting the caster and the camber angles, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - When checking the left and the right side caster and camber, it must be equal within 1.0 degree. - When setting the left and the right side caster and camber, it must be equal within 0.50 degree. - The caster and the camber set is relative to the ground. 1. Loosen the upper control arm shaft to frame nuts (1). Important: A normal shim pack will leave at least 24/~ threads of the bolt exposed beyond the nut. The maximum shim pack cannot be thicker than 21.3 mm (0.84 inch). - The difference between the front shim packs and the rear shim packs must not exceed 10 mm (0.40 inch). If these requirements cannot be met, check for damaged control arms and damaged related parts. 2. If the caster is not within specifications, adjust the caster by transferring the front shims to the rear, or the rear shims to the front. The transfer of the one shim from the rear bolt to the front bolt will decrease the positive caster. 3. If the camber is not within specification, adjust the camber by changing the shims at both the front and the rear of the shaft. Add or subtract the shims (2) as required. Adding an equal number of shims at both the front and rear of the cross shaft will decrease positive camber. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the nut on the thinner shim pack first. - Tighten the nuts to 110 Nm (81 ft. lbs.). Tightening the nut on the thinner shim pack first improves the shaft to frame clamping force and torque retention. 5. Check the toe-in after changing the caster or the camber. Front Wheel Toe Adjustment Front Toe Adjustment The toe-in can be increased or decreased by changing the length of the tie rods. A threaded sleeve is provided for this purpose. When the tie rods are mounted ahead of the steering knuckle, the tie rods must be modified as follows: Decreased in length in order to increase the toe-in. Increased in length in order to decrease the toe-in. Important: When checking and setting the toe-in, the left and right side to be set separately and the steering wheel must be held straight ahead position within 4 - 6 degrees. Before adjusting the toe-in, jounce the front bumper 3 times to allow the vehicle to return to the normal height. - Adjust the toe-in with the vehicle at curb height. The front suspension Z dimension and the rear suspension D dimension are indicated in Trim Heights. - For an accurate toe-in reading, do not push or pull on the tires during the alignment process. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 6796 1. Set the steering wheel in the straight ahead position. 2. Loosen the clamp bolts at each end of the steering tie rod adjustable sleeves. Important: The tie rod adjuster often becomes rusted in service. 3. If the torque needed to rotate the adjuster tube exceeds 9 Nm (80 inch lbs.), perform the following steps: 3.1. Remove the adjuster tube clamp nuts and the bolts. Discard the nuts and the bolts. 3.2. Apply the penetrating oil between the adjuster tube and the tie rod threads. 3.3. Rotate the adjuster tube until the tube moves freely. 3.4. Install the new bolts and the nuts with the correct part number. The nut must be towards the front of the vehicle. 4. Rotate the inner and the outer tie rod sockets rearward to the limit of the ball stud travel. 5. Turn the tie rod adjusting sleeves to set the toe-in to specifications. Notice: Refer to Fastener Notice in Service Precautions. Important: Before tightening the adjuster tube nuts, do the following: Check the number of threads on each tie rod within the adjuster tube. The tie rod threads within the adjuster tube must be equal to within 3 threads. - Check the relationship of the adjuster tube to the clamp. The adjuster tube slot and the clamp opening must not be in the same position. The position of the adjuster tube clamp must not exceed 30 degrees in either direction. - The adjuster tube clamp must be on the inside of the adjuster tube dimple. 6. Tighten the adjuster tube clamp nuts. - Tighten the adjuster tube clamp nuts to 25 Nm (18 ft. lbs.). The clamp ends may touch when the nuts are tightened to specification. 7. Rotate the tie rod sockets to the centered position. Ensure that the outer socket is square with the stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications Connecting Rod to Pitman Arm Nut 48 ft. lbs. Connecting Rod to Relay Rod 35 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement Center Link: Service and Repair Connecting Rod Replacement Connecting Rod Replacement - Tools Required J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the prevailing torque nut (5) from the connecting rod (1) ball stud. Discard the prevailing torque nut (5). 3. Use the J24319-B in order to remove the connecting rod (1) from the relay rod (4). 4. Remove the prevailing torque nut (2) from the pitman arm (3) ball stud. Discard the prevailing torque nut (2). 5. Use the J24319-B in order to remove the connecting rod (1) from the pitman arm (3). 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seals for excessive wear. 8. Clean the threads on the ball stud. Installation Notice: Refer to Fastener Notice in Service Precautions. 1. Use the J 29193 in order to connect the connecting rod to the pitman arm ball stud. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. Remove the J29193. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6815 2. Install the new prevailing torque nut (2) to the pitman arm (3) ball stud. - Tighten the nut to 62 Nm (48 ft. lbs.). 3. Use the J 29193 in order to install the connecting rod (1) ball stud to the relay rod (4). Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J 29193. 5. Install the new prevailing torque nut (5) to the ball stud. - Tighten the nut to 47 Nm (35 ft. lbs.). 6. Lower the vehicle. 7. Adjust the toe-in. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6816 Center Link: Service and Repair Relay Rod Replacement Relay Rod Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the inner tie rods (5) from the relay rod. 3. Remove the prevailing torque nut (5) from the connecting rod (1) ball stud. Discard the prevailing torque nut (5). 4. Use the J24319-B in order to remove the connecting rod from the relay rod. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6817 5. Remove the prevailing torque nuts (5) from the idler arm (1) ball studs. Discard the prevailing torque nuts (1). 6. Use the J24319-B in order to remove the relay rod from the idler arms. 7. Inspect the threads on the tie rod for damage. 8. Inspect the ball stud threads for damage. 9. Inspect the ball stud seals for excessive wear. 10. Clean the threads on the ball studs. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Use the J29193 in order to install the relay rod to the idler arm ball studs. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 2. Remove the J29193. 3. Install the new prevailing torque nut (5) to the idler arm (1) ball studs. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Connecting Rod Replacement > Page 6818 4. Use the J 29193 in order to install the relay rod to the connecting rod ball stud. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 5. Remove the J29193. 6. Install the new prevailing torque nut (5) to the connecting rod (1) ball stud. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 7. Use the J29193 in order to install the inner tie rod (5) to the relay rod (8). Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 8. Remove the J 29193. 9. Install the new prevailing torque nut (7) to the inner tie rod (5). - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 10. Lower the vehicle. 11. Adjust the toe-in. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Steering Knuckle to Tie Rod End Nut 35 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6822 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 23742 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 2. Support the lower control arm with a safety stand. 3. Remove the tire and wheel. 4. Remove the wheel hub and bearing assembly. 5. Remove the outer tie rod to steering knuckle retaining nut. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6823 6. Disconnect the tie rod end from the steering knuckle using J 24319-B. 7. Remove the steering knuckle gasket only if the steering knuckle is being repaired or replaced. 8. Remove the upper and lower control arms cotter pins and the retaining nuts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6824 9. Remove the upper ball joint stud from the steering knuckle using J 23742. 10. Raise the upper control arm. Disengage the upper ball joint from the steering knuckle. 11. Disconnect the steering knuckle from the lower ball joint using J 23742. 12. Remove the steering knuckle from the vehicle. 13. Clean the steering knuckle with solvent, then air dry. 14. Inspect the steering knuckle tapered holes that attach to the ball joints and the outer tie rod. Replace the steering knuckle if any of the 3 holes are out-of-round, deformed, or damaged. 15. Inspect the spindle for wear or damage. Installation Procedure 1. Connect the steering knuckle to the lower ball joint. Press the steering knuckle onto the lower ball joint until the lower ball joint is fully seated. 2. Connect the steering knuckle to the upper ball joint. Lower the upper control arm in order to seat the upper ball joint into the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6825 3. Install the upper and lower ball joint retaining nuts. - Tighten the upper ball joint retaining nut to 83 Nm (61 ft. lbs.). - Tighten the lower ball joint retaining nut to 125 Nm (90 ft. lbs.). 4. Install new cotter pins. Tighten the upper and lower ball joint nuts up to an additional 1/6 amount to insert the cotter pin through the nuts. Bend the cotter pin flat against the nut. 5. Install the steering knuckle gasket, if necessary. 6. Connect the outer tie rod to the steering knuckle. 7. Install the outer tie rod retaining nut. - Tighten the outer tie rod retaining nut to 47 Nm (35 ft. lbs.). 8. Install the rotor/hub assembly. 9. Install the tire and wheel. 10. Remove the safety stand from the lower control arm. 11. Lower the vehicle. 12. Check the front wheel alignment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications Idler Arm to Frame Bolts 77 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6829 Idler Arm: Service and Repair Idler Arm Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all of the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the bolts (3) from the idler arm (4). 3. Remove the prevailing torque nut (2) from the idler arm (4) ball stud. Discard the prevailing torque nut (2). 4. Use the J 24319-B in order to remove the relay rod (1) from the idler arm (4). 5. Remove the idler arm (4). 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seal for cuts or other damage. 8. Clean the threads on the ball stud and in the ball stud nut. Installation Procedure 1. Install the idler arm (4) to the frame. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the idler arm to frame mounting bolts (3). - Tighten the idler arm to frame mounting bolts to 105 Nm (77 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6830 3. Use the J29193 in order to install the relay rod to the idler arm ball stud. Ensure that the seal is on the stud. Tighten the J29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J29193. 5. Install the new prevailing torque nut (2) to the idler arm (4) ball stud. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 6. Lower the vehicle. 7. Adjust the toe-in. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications Pitman Arm to Steering Gear Nut 184 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 6834 Pitman Arm: Service and Repair Pitman Arm Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 29107-A Pitman Arm Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all of the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the prevailing torque nut (2) from the connecting rod (1) ball stud at the pitman arm (3). Discard the prevailing torque nut (2). 3. Use the J24319-B in order to remove the connecting rod from the pitman arm. 4. Remove the prevailing torque nut and the washer from the steering gear shaft. - Discard the prevailing torque nut. - Mark the pitman arm and the pitman shaft in order to permit proper alignment during assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 6835 Notice: Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result. 5. Use the J29107-A in order to remove the pitman arm (1). 6. Inspect the ball stud threads for damage. 7. Inspect the ball stud seals for excessive wear. 8. Clean the threads on the ball stud and the ball stud nut. Installation Procedure 1. Align the marks made on the pitman arm during removal in order to install the pitman arm on the pitman shaft. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the washer and the new prevailing torque nut to the pitman shaft. - Tighten the pitman arm prevailing torque nut to 250 Nm (185 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 6836 3. Use the J29193 in order to install the connecting rod ball stud to the pitman arm. Ensure that the seal is on the stud. - Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J 29193. 5. Install the new prevailing torque nut (2) to the connecting rod (1) ball stud at the pitman arm (3). - Tighten the connecting rod to pitman arm prevailing torque nut to 62 Nm (48 ft. lbs.). 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Bleeding the Power Steering System - Tools Required J 35555 Metal Mity vac - J 43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 in Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7 - 10 kPa (2 - 3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis. 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. 11. Start the engine. Allow the engine to idle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6841 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180-360 degrees in both directions 5 times. 16. Switch the ignition off. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 17. Verify the fluid level. 18. Remove the pump reservoir cap. 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 in Hg) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6842 25. Reinstall the pump reservoir cap. Excessive Vacuum Drop Diagnosis 1. If the vacuum continues to drop, remove the pressure and return hose from the pump. 2. Install the plugs (1,2) supplied with the J 43485 into the pressure and return port. 3. Attach the J 43485 to the J 35555 or equivalent. 4. Place the J 43485 on or in the pump reservoir filler neck. 5. Apply a vacuum of 68 kPa (20 in Hg) maximum. 6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system. Important: Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose. Fluid must be free from discoloration. 7. Observe the fluid. 8. If condition persists, replace the following parts: - The return hose clamps - The return hose O-rings - The pressure hose O-rings Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6843 - The gear cylinder line O-rings - The reservoir to pump O-ring 9. Repeat the bleed procedure from the beginning. 10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface. 11. Verify the following conditions: - There is smooth power assist. - The vehicle operates quietly. - The pump maintains the proper fluid level. - There is not any leaking in the steering system. - The fluid is free of foam or discoloration. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering System GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Remote Reservoir Mounting Bolts 35 inch lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle Power Steering Reservoir Replacement -Off Vehicle Disassembly Procedure 1. Drain the power steering fluid from the power steering pump. 2. Remove the pump mounting studs (2). 3. Remove the connector and fitting assembly (4). 4. Remove the O-ring seal (3) from the connector and fitting assembly (4). 5. If replacement is required, remove the control valve assembly and the flow control spring from the pump housing assembly. 6. Remove the reservoir assembly (1) from the pump housing assembly (2). 7. Remove the O-ring seals (1), (4) and (5). 8. Remove the magnet (3). 9. Clean the magnet (3). 10. Inspect the Welch plug in the power steering pump housing (2). Do not remove. If the Welch plug is deformed or dislodged, replace the power Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6852 steering pump. Assembly Procedure Important: Use new O-ring seals when assembling the power steering pump assembly. 1. Lubricate the O-ring seals (1), (4) and (5) with power steering fluid. 2. To install the control valve assembly and flow control spring to the pump housing assembly (2); refer to Power Steering Pump Flow Control Valve Replacement - Off Vehicle. 3. Install the O-ring seals (1), (4) and (5) to the pump housing assembly (2). 4. Install the magnet (3) to the pump housing assembly (2). 5. Connect the reservoir assembly (1) to the pump housing assembly (2). 6. Install the O-ring seal. 7. Install the connector and fitting assembly (4) to the pump housing (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6853 Notice: Refer to Fastener Notice in Service Precautions. 8. Install the pump mounting studs (2) to the pump housing (1). - Tighten the pump mounting studs (2) to 58 Nm (43 ft. lbs.). - Tighten the connector and fitting assembly (4) to 75 Nm (55 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6854 Power Steering Fluid Reservoir: Service and Repair Remote Power Steering Fluid Reservoir Replacement Remote Power Steering Fluid Reservoir Replacement Removal Procedure 1. Place drain pan under the vehicle. 2. Draw all of the fluid out of the reservoir in order to avoid spills. 3. Disconnect the hydraulic brake booster hose from the power steering reservoir. 4. Disconnect the power steering reservoir to the power steering pump hose from the power steering reservoir. 5. Remove the power steering reservoir mounting bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6855 6. Remove the power steering reservoir. Installation Procedure 1. Install the power steering reservoir. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the power steering reservoir mounting bolts. - Tighten the power steering reservoir mounting bolts to 4 Nm (35 inch lbs.). 3. Connect the power steering reservoir to the power steering pump hose to the power steering reservoir. 4. Connect the hydraulic brake booster hose to the power steering reservoir. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Power Steering Reservoir Replacement - Off Vehicle > Page 6856 5. Bleed the power steering system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: Customer Interest Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 6865 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight Power Steering Line/Hose: All Technical Service Bulletins Steering - Whistle Noise When Driving Straight Bulletin No.: 03-02-32-047 Date: October 23, 2003 TECHNICAL Subject: Whistle Noise from Front of Vehicle (Install Power Steering Hose Adapter) Models: 2002-2003 Chevrolet Astro Van Models 2002-2003 GMC Safari Van Models Condition Some customers may comment on a whistle noise from the front of the vehicle, but noise will quit when turning the steering wheel. Cause Interaction with the fluid flow through the pressure port and the poppet valve at the power steering (PS) gear box may cause this condition. Correction Install an adapter and 0-ring to the PS gear box high pressure inlet using the following procedure. 1. Remove the return line from the PS gear box in order to gain access to the high pressure line. 2. Remove the high pressure line from the PS gear box. 3. Install the adapter and 0-ring to the PS gear box high pressure inlet. Tighten Tighten to 27.5 N.m (21 lb ft). 4. Install the high pressure line and 0-ring to the adapter. Tighten Tighten to 27.5 N.m (21 lb ft). 5. Install the return line and 0-ring to the PS gear box. Tighten Tighten to 27.5 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 03-02-32-047 > Oct > 03 > Steering - Whistle Noise When Driving Straight > Page 6871 6. Bleed the PS system. 7. Clean the area with brake cleaner. 8. Inspect for leaks. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 6872 Power Steering Line/Hose: Specifications Power Steering Hose Fittings 20 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement Power Steering Line/Hose: Service and Repair P/S Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Disconnect the power steering cooler hose from the steering pump. 2. Raise the vehicle. Refer to Vehicle Lifting. 3. Install a drain pan under the vehicle. 4. Disconnect the power steering cooler pipe hose from the steering gear. 5. Remove the power steering cooler pipe (2) from the air baffle (3). 6. Remove the power steering cooler pipe from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6875 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe (2) to the air baffle (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the power steering cooler pipe to the steering gear. - Tighten the power steering cooler pipe to the steering gear to 27 Nm (20 ft. lbs.). 4. Lower the vehicle. 5. Connect the power steering cooler hose to the steering pump. 6. Bleed the power steering system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6876 Power Steering Line/Hose: Service and Repair Power Brake Booster Inlet Hose Replacement Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the hydraulic brake booster inlet hose from the of the power steering pump. 3. Lower the vehicle. 4. Disconnect the hydraulic brake booster inlet hose from the hydraulic brake booster. 5. Remove the hydraulic brake booster inlet hose from vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6877 1. Install the hydraulic brake booster inlet hose to vehicle. 2. Connect the hydraulic brake booster inlet hose to the hydraulic brake booster. 3. Raise the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 4. Connect the hydraulic brake booster inlet hose to the power steering pump. - Tighten the hydraulic brake booster inlet hose to the power steering pump to 27 Nm (20 ft. lbs.). 5. Bleed the system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6878 Power Steering Line/Hose: Service and Repair Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Removal Procedure Important: Note the position of all the tie-straps, power steering hoses and the hose insulators for proper re-installation. 1. Remove the power brake booster outlet hose tie-straps. 2. Place a drain pan under the vehicle. 3. Disconnect the power steering cooler hose from the power steering gear. 4. Disconnect the hydraulic brake booster outlet hose from the steering gear. 5. Disconnect the hydraulic brake booster outlet hose from the hydraulic brake booster. 6. Remove the hydraulic brake booster outlet hose from the vehicle. Installation Procedure Notice: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > P/S Cooler Pipe/Hose Replacement > Page 6879 1. Install the hydraulic brake booster outlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Connect the hydraulic brake booster outlet hose to the hydraulic brake booster. - Tighten the hydraulic brake booster outlet hose to the hydraulic brake booster to 27 Nm (20 ft. lbs.). 3. Connect the hydraulic brake booster outlet hose to the power steering gear. - Tighten the hydraulic brake booster outlet hose to the power steering gear to 27 Nm (20 ft. lbs.). 4. Remove the drain pan. 5. Install the hydraulic brake booster outlet hose tie straps. 6. Bleed the system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Power Steering Pump Control Valve Fitting 55 ft. lbs. Power Steering Pump Mountings Bolts 37 ft. lbs. Power Steering Pump Mounting Nut 30 ft. lbs. Power Steering Pump Mounting Studs 43 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6887 Power Steering Pump Disassembled View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6888 Power Steering Pump: Testing and Inspection Please see STEERING/TESTING and INSPECTION for information on this component. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Replacement Power Steering Pump Flow Control Valve Replacement - Off Vehicle Disassembly Procedure 1. Drain the oil from the reservoir (1). 2. Remove the connector and fitting assembly (2). 3. Remove the control valve assembly (4) from the pump housing (1). Make sure the flow control spring (5) does not fall out of the pump housing (1). 4. Remove and discard the O-ring seal (3) from the connector and fitting assembly (2). Assembly Procedure 1. Install the flow control spring (5), if removed from the pump housing (1). 2. Lubricate the new O-ring seal (3) with power steering fluid. 3. Install the O-ring seal (3) onto the connector and fitting assembly (2). 4. Install the control valve assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the connector and fitting assembly (2). - Tighten the connector and fitting assembly to 75 Nm (55 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6891 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement Power Steering Pulley Replacement - Tools Required J 25034-C Power Steering Pump Pulley Remover - J 25033-C Power Steering Pump Pulley Installer Removal Procedure 1. Remove the lower fan shroud. 2. Remove the drive belt. 3. Remove the power steering pump pulley using the J 25034-C. Installation Procedure 1. Place the power steering pump pulley on the end of the power steering pump shaft. 2. Install the power steering pump pulley using J 25033-C. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6892 3. Ensure that the power steering pump pulley (1) is flush against the power steering pump shaft (2), with an allowable variance of 0.25 mm (0.010 inch). 4. Install the drive belt. 5. Install the lower fan shroud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6893 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement Removal Procedure 1. Remove the power steering pump pulley. 2. Place a drain pan under the vehicle. Important: Cap or plug the ends of the power steering hoses to prevent fluid loss. 3. Disconnect the power brake booster inlet hose from the power brake booster. 4. Disconnect the power steering cooler hose from the power steering pump. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6894 5. Disconnect the power steering pump remote reservoir hose from the power steering pump. 6. Raise and support the vehicle. Refer to Vehicle Lifting. 7. Remove the power steering pump rear mounting bracket nut. 8. Lower the vehicle. 9. Loosen the accessory bracket bolts and nut. Pull the accessory bracket forward. 10. Remove the power steering pump mounting bolts. 11. Remove the power steering pump and the power brake booster inlet hose from the vehicle. 12. Remove the power brake booster inlet hose from the power steering pump. Installation Procedure 1. Install the power brake booster inlet hose to the power steering pump. 2. Install the power steering pump and the power brake booster inlet hose to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pump mounting bolts. - Tighten the power steering pump mounting bolts to 50 Nm (37 ft. lbs.). 4. Reposition the accessory mounting bracket and tighten the bolts and nut. - Tighten the accessory mounting bracket bolts to 50 Nm (37 ft. lbs.). - Tighten the accessory mounting bracket nut to 41 Nm (30 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Replacement > Page 6895 5. Raise the vehicle. Refer to Vehicle Lifting. 6. Install the power steering pump rear mounting bracket nut. - Tighten the power steering pump rear mounting bracket nut to 41 Nm (30 ft. lbs.). 7. Lower the vehicle. 8. Uncap the ends of the power steering hoses. 9. Connect the power steering pump remote reservoir hose to the power steering pump. 10. Connect the power steering cooler hose to the power steering pump. 11. Connect the power brake booster inlet hose to the power brake booster. - Tighten the power brake booster inlet hose to the power brake booster to 27 Nm (20 ft. lbs.). 12. Remove the drain pan from under the vehicle. 13. Install the power steering pump pulley. 14. Bleed the power steering system. 15. Inspect the power steering pump for leaks and the hoses for proper clearance from the frame and from other components. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 6901 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair Steering Gear Seal: Service and Repair Pitman Shaft Seal Replacement On Vehicle - Tools Required J 4245 Internal Snap Ring Pliers - J 6219 Pitman Shaft Seal Installer Removal Procedure 1. Remove the pitman arm. 2. Remove the snap ring (1) using J 4245. 3. Remove the following components from the power steering gear (1): 3.1. The dust seal (5) 3.2. The return ring (4) 3.3. The washer (3) 3.4. The pitman shaft oil seal (2) 4. Inspect the Pitman shaft surface for roughness or pitting. Replace the pitman shaft if the shaft is pitted. 5. Clean the pitman shaft and seal areas using a wire brush. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Page 6906 1. Lubricate the new seals with grease. 2. Apply a single layer of tape to the pitman shaft in order to avoid damaging the seals. 3. Install the pitman shaft oil seal (2) and washer (3) to the power steering gear. 4. Use the J 6219 to install the pitman shaft seal and washer to the power steering gear. The seal should be in far enough to install the return ring, dust seal, and the snap ring. 5. Install the return ring and the dust seal to the power steering gear. 6. Use J 6219 in order to seat the return ring and the dust seal in the power steering gear. 7. Install the snap ring to the pitman shaft using J 4245. 8. Install the pitman arm. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Intermediate Shaft to Steering Gear Pinch Bolt 30 ft. lbs. Intermediate Shaft to Steering Column Pinch Bolt 30 ft. lbs. Intermediate Shaft to Steering Gear Pinch Bolt 30 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6910 Steering Shaft: Service and Repair "For information regarding this component please refer to steering column service and repair" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Nut 30 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6914 Steering Wheel: Description and Operation STEERING WHEEL AND COLUMN The steering wheel and column are designed to absorb energy when driver contact is made with the steering wheel or inflated air bag. In a frontal collision the driver may contact the steering wheel directly or load the steering wheel and column through the inflated air bag. When the driver applies load to the air bag or steering wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damage after a collision. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications Tie Rod: Specifications Adjuster Tube Clamp Bolts 18 ft. lbs. Tie Rod to Relay Rod Nut 35 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6918 Tie Rod: Service and Repair Tie Rod Replacement - Tools Required J 6627-A Tie Rod Puller - J 24319-B Steering Linkage and Tie Rod Puller - J 29193 Steering Linkage Installer (12 mm) Removal Procedure Important: Use the proper tool in order to separate all of the tie rods and the ball joints. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the cotter pin and the castellated nut from the outer tie rod. 3. Remove the prevailing torque nut from the inner tie rod. Discard the prevailing torque nut. Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint. 4. Use the J 24319-B in order to remove the outer tie rod ball stud from the steering knuckle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6919 5. Use the J 6627-A in order to remove the inner tie rod from the relay rod. 6. Loosen the adjuster tube clamp bolts (3). 7. Unscrew the tie rod ends from the adjuster tube (4). 8. Remove the inner tie rod ends (5) from the adjuster tube (4). 9. Inspect the following components for damage: - The threads on the tie rod (1, 5) - The ball stud threads - The adjuster tube (4) for bending or damaged threads - The tie rod end seals for excessive wear 10. Clean the threads on the ball stud and in the ball stud nut. 11. Clean the tapered surfaces. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6920 Lubricate the tie rod threads with chassis lubricant if the tie rod ends were removed from the adjuster tube. 1. Loosen the clamps (2) on the adjuster tube (4). 2. Install the tie rod ends to the adjuster tube (4). The number of threads on the inner tie rod (5) and the outer tie rod (1) ends must be equal within 3 threads. Notice: Refer to Fastener Notice in Service Precautions. 3. Use the J29193 in order to install the inner tie rod to the relay rod. Ensure that the seal is on the stud. Tighten the J 29193 to 54 Nm (40 ft. lbs.) in order to seat the tapers. 4. Remove the J 29193. 5. Install the new prevailing torque nut to the inner tie rod. - Tighten the prevailing torque nut to 47 Nm (35 ft. lbs.). 6. Install the outer tie rod ball stud to the steering knuckle. Ensure that the seal is on the stud. Important: Tighten the castellated nut up to an additional 1/6 amount in order to insert the cotter pin through the outer tie rod ball stud. Do not back the nut off in order to align the cotter pin hole. 7. Install the castellated nut. - Tighten the castellated nut to 47 Nm (35 ft. lbs.). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Specifications > Page 6921 8. Install the new cotter pin. Bend the cotter pin ends flat against the nut flats. 9. Lower the vehicle. 10. Adjust the toe-in. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint to Lower Control Arm 22 ft. lbs. Lower Ball Joint to Steering Knuckle Nut 90 ft. lbs. Lower Ball Joint Wear limit 0.125 in Ball Joint to Upper Control Arm 22 ft. lbs. Upper Ball Joint to Steering Knuckle Nut 61 ft. lbs. Upper Ball Joint Wear Limit See Note Disconnect the upper ball joint from the steering knuckle. If you find any looseness or can twist the stud with your fingers, replace the upper ball joint. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 6926 Ball Joint: Testing and Inspection Ball Joint Inspection - Tools Required J 8001 Dial indicator Important: The vehicle must rest on a level surface. - The vehicle must be stable. Do not rock the vehicle on the jack stands. - The upper control arm bumper must not contact the frame. 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Support the lower control arm with a jack stand, as far outboard as possible, near the lower ball joint. Important: If a seal is cut or torn, replace the ball joint. 3. Wipe the ball joints clean. Check the seals for cuts or tears. 4. Check the wheel bearings for looseness. If looseness in the wheel bearings is present, refer to Wheel Bearings Diagnosis (Sealed) or Wheel Bearings Diagnosis (Tapered). 5. Check the ball joints for horizontal looseness. 5.1. Position the J 8001 dial indicator against the lowest outboard point on the wheel rim. 5.2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in both joints. 5.3. The dial indicator reading should be no more than 3.18 mm (0.125 inch). If the reading is too high, check the lower ball joints for vertical looseness. 6. Check the lower ball joints for wear and for vertical looseness using the following procedure: 6.1. Inspect by sight the lower ball joint for wear. The position of the housing into which the grease fitting is threaded indicates wear. This round housing projects 1.27 mm (0.050 inch) beyond the surface of the lower ball joint cover on a new ball joint Under normal wear, the surface of the lower ball joint housing retreats inward very slowly. 6.2. First observe, then scrape a scale, screwdriver, or a fingernail across the cover. If the round housing is flush with or inside of the cover surface, replace the lower ball joint. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 6927 7. Place a J 8001 dial indicator (1) against the spindle in order to show vertical movement. 8. Pry between the lower control arm (2) and the outer bearing race (1) while reading the dial indicator. This shows vertical looseness in the ball joints. The lower ball joint is not preloaded and may show some looseness. 9. If the dial indicator reading is more than 3.18 mm (0.125 inch), replace the lower ball joint. 10. If the lower ball joint is within specifications, and there is too much horizontal looseness, check the upper ball joint for wear. 10.1. Disconnect the upper ball joint from the steering knuckle. 10.2. If you find any looseness or can twist the stud with your fingers, replace the upper ball joint. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint Lower Ball Joint Replacement - Tools Required J 9519-E Lower Ball Joint Remover and Installer Set - J 23742 Ball Joint Separator Removal Procedure Caution: Floor jack must remain under the lower control arm during removal and Installation to retain the lower control arm In position. Failure to do so could result in personal injury. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the lower control arm with a safety stand. 3. Remove the tire and wheel. 4. Remove the lower ball joint cotter pin and the retaining nut. 5. Break the lower ball joint loose from the steering knuckle using J 23742. 6. Remove J 23742. 7. Pull the steering knuckle free from the lower ball joint. 8. Support the steering knuckle in order to prevent the steering knuckle weight from damaging the brake hose. 9. Remove the rubber grease seal from the lower ball joint. 10. Remove the lower ball joint grease fining. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 6930 11. Remove the lower ball joint from the lower control arm using J9519-E. Installation Procedure 1. Install the lower ball joint to the lower control arm. 2. Press the lower ball joint into the lower control arm using J 9519-E. Press in until the ball joint bottoms in the control arm. 3. Install the grease seal and the grease fitting to the lower ball joint. - The grease-purge hole of the seal must face inboard. - Press the grease seal into place. The seal must be fully seated on the ball joint. 4. Remove the steering knuckle support. 5. Install the lower ball joint to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the lower ball joint retaining nut. - Tighten the lower ball joint retaining nut to 125 Nm (90 ft. lbs.). 7. Install a new cotter pin. Tighten the nut up to an additional 1/6 amount in order to insert the cotter pin through the lower ball joint stud. Bend the pin ends against the nut flats. 8. Using a grease gun, grease to the lower ball joint until grease appears at the lower ball joint grease seal. 9. Install the tire and wheel. 10. Remove the safety stand from the lower control arm. 11. Lower the vehicle. 12. Check the front wheel alignment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 6931 Ball Joint: Service and Repair Upper Ball Joint Upper Ball Joint Replacement - Tools Required J 23742 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 2. Support the lower control arm with a safety stand. 3. Remove the tire and wheel. 4. Disconnect the wheel speed sensor connector from the upper control arm. 5. Remove the cotter pin and the upper ball joint retaining nut. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 6932 6. Separate the upper ball joint from the steering knuckle using J 23742. Apply pressure on the tool until the stud breaks loose. 7. Remove J 23742. 8. Pull the steering knuckle free from the upper ball joint. 9. Support the steering knuckle in order to prevent the steering knuckle weight from damaging the brake hose. 10. Use a 3.175 mm (1/8 inch) drill bit in order to cut 6.35 mm (1/4 inch) deep holes in the center of each rivet head. 11. Drill away the rivet heads using a 12.7 mm (1/2 inch) drill bit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 6933 12. Using a small pin punch, punch out the rivets. 13. Remove the upper ball joint from the upper control arm. Installation Procedure 1. Install the upper ball joint to the upper control arm. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper ball joint to upper control arm mounting bolts and nuts. - Tighten the upper ball joint to upper control arm mounting nuts to 30 Nm (22 ft. lbs.). 3. Remove the steering knuckle support. 4. Connect the upper ball joint to the steering knuckle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 6934 5. Install the upper ball joint retaining nut. - Tighten the upper ball joint retaining nut to 83 Nm (61 ft. lbs.). 6. Install a new cotter pin. Tighten the nut up to an additional 1/6 amount in order to insert the cotter pin through the upper ball joint stud. Bend the pin ends flat against the nut flats. 7. Connect the wheel speed sensor connector. 8. Install the upper ball joint grease fitting. 9. Using a grease gun, grease the upper ball joint until grease appears at the upper ball joint grease seal. 10. Install the tire and wheel. 11. Remove the safety stands from the lower control arm. 12. Lower the vehicle. 13. Check the front wheel alignment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair Upper Control Arm Bushings Replacement - Tools Required J 22269-01 Accumulator and Servo Piston Remover Removal Procedure 1. Remove the upper control arm. 2. Mount the upper control arm in a vise. 3. Remove the upper control arm shaft nuts and the retainers. 4. Remove the upper control arm bushings. Use the J22269-01, a slotted washer, and a short piece of pipe slightly larger than the bushing. 5. Remove the upper control arm shaft from the upper control arm. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 6939 1. Install the upper control arm shaft into the upper control arm. 2. Install the upper control arm bushings into the upper control arm. Use the J 22269-01 and a short piece of pipe that is the same outer diameter as the rubber bushing. 3. Tighten the J 22269-01 until the bushing is positioned on the shaft and the control arm as shown. The measurement should be 12.1 - 13.8 mm (0.48 - 0.52 inch) on both ends. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 6940 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper control arm shah retainers and the retaining nuts. - Tighten the upper control arm shaft retaining nuts to 115 Nm (85 ft. lbs.). 5. Install the upper control arm to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody Cross-Member: Service and Repair Frame and Underbody Crossmember Brace Replacement - Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the bolts that retain the forward edge of the crossmember brace to the frame. 3. Remove the bolts and the nuts that retain the rear edge of the crossmember brace to the frame. 4. Remove the crossmember brace from the frame. Installation Procedure 1. Install the crossmember brace to the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts and the nuts in order to retain the rear edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts and the nuts to 35 N.m (26 lb ft). 3. Install the bolts that retain the forward edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts to 35 N.m (26 lb ft). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6945 Cross-Member: Service and Repair Frame Stop Replacement Frame Stop Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the bolts that retain the frame stop to the frame. 3. Remove the frame stop. Installation Procedure 1. Install the frame stop. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the frame stop to the frame. Tighten the bolts that retain the frame stop to 35 N.m (26 lb ft). 3. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6946 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) in General Information. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Remove the transmission support nuts and bolts. 5. Remove the transmission support from the vehicle. Installation Procedure 1. Install the transmission support to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the transmission support nuts and bolts. Tighten the nuts and bolts to 70 N.m (52 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 6947 3. Install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Steering Knuckle to Tie Rod End Nut 35 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6951 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement - Tools Required J 24319-B Steering Linkage and Tie Rod Puller - J 23742 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Caution: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury. 2. Support the lower control arm with a safety stand. 3. Remove the tire and wheel. 4. Remove the wheel hub and bearing assembly. 5. Remove the outer tie rod to steering knuckle retaining nut. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6952 6. Disconnect the tie rod end from the steering knuckle using J 24319-B. 7. Remove the steering knuckle gasket only if the steering knuckle is being repaired or replaced. 8. Remove the upper and lower control arms cotter pins and the retaining nuts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6953 9. Remove the upper ball joint stud from the steering knuckle using J 23742. 10. Raise the upper control arm. Disengage the upper ball joint from the steering knuckle. 11. Disconnect the steering knuckle from the lower ball joint using J 23742. 12. Remove the steering knuckle from the vehicle. 13. Clean the steering knuckle with solvent, then air dry. 14. Inspect the steering knuckle tapered holes that attach to the ball joints and the outer tie rod. Replace the steering knuckle if any of the 3 holes are out-of-round, deformed, or damaged. 15. Inspect the spindle for wear or damage. Installation Procedure 1. Connect the steering knuckle to the lower ball joint. Press the steering knuckle onto the lower ball joint until the lower ball joint is fully seated. 2. Connect the steering knuckle to the upper ball joint. Lower the upper control arm in order to seat the upper ball joint into the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6954 3. Install the upper and lower ball joint retaining nuts. - Tighten the upper ball joint retaining nut to 83 Nm (61 ft. lbs.). - Tighten the lower ball joint retaining nut to 125 Nm (90 ft. lbs.). 4. Install new cotter pins. Tighten the upper and lower ball joint nuts up to an additional 1/6 amount to insert the cotter pin through the nuts. Bend the cotter pin flat against the nut. 5. Install the steering knuckle gasket, if necessary. 6. Connect the outer tie rod to the steering knuckle. 7. Install the outer tie rod retaining nut. - Tighten the outer tie rod retaining nut to 47 Nm (35 ft. lbs.). 8. Install the rotor/hub assembly. 9. Install the tire and wheel. 10. Remove the safety stand from the lower control arm. 11. Lower the vehicle. 12. Check the front wheel alignment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft insulator bracket bolts. 3. Remove the stabilizer shaft insulator bracket. 4. Using a pry bar, lower the stabilizer shaft. 5. Remove the stabilizer shaft insulator. Installation Procedure 1. Using a pry bar, lower the stabilizer shaft. 2. Install the stabilizer shaft insulator to the stabilizer shaft. Position the slit on the stabilizer shaft insulator toward the front of the vehicle. 3. Install the stabilizer shaft bracket over the stabilizer shaft insulator. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the stabilizer shaft bracket retaining bolts. - Tighten the stabilizer shaft bracket retaining bolts to 36 Nm (27 ft. lbs.). 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft link nut. 4. Remove the retainer and insulator from the stabilizer shaft link bolt. 5. Remove the stabilizer shaft link bolt, retainers, insulators, and stabilizer shaft link by pulling the bolt down through the stabilizer shaft and lower control arm. Installation Procedure 1. Install the retainer and the insulator to the stabilizer shaft link bolt. Position the parts correctly. 2. Install the stabilizer shaft link bolt through the lower control arm hole. 3. Install the stabilizer shaft link retainers, insulators, and stabilizer shaft link to the stabilizer shaft link bolt. 4. Insert the stabilizer shaft link bolt through the stabilizer shaft and install the stabilizer shaft link insulator and retainer. 5. Install the stabilizer shaft link bolts through the stabilizer shaft. 6. Install the insulators and retainers to the stabilizer shaft link bolt. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the stabilizer shaft link retaining nut to the stabilizer shaft link bolt. ^ Tighten the stabilizer shaft link retaining nut to 17 Nm (13 ft. lbs.). 8. Install the tire and wheel. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Suspension Spring ( Coil / Leaf ): Customer Interest Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6970 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6971 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6972 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6973 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Drivetrain - Booming Noise at Highway Speeds Bulletin No.: 00-03-09-001A Date: July 29, 2003 TECHNICAL Subject: Rolling Boom Noise Inside Vehicle (Install Pinion Nose Damper and/or New Rear Leaf Spring Dampers) Models: 1995-2004 Chevrolet Astro Van Models 1995-2004 GMC Safari Van Models Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-03-09-001 (Section 03 - Suspension). Condition Some owners may comment about a "boom" noise inside the vehicle while driving at speeds ranging between 97-105 km/h (60-65 mph). This condition is most noticeable from behind the driver's seat. Cause The condition may result from an engine-firing harmonic, which becomes noticeable at torque converter clutch (TCC) lock-up. Correction A new rear leaf spring damper kit (one per spring) has been developed, to be used in conjunction with a pinion nose damper tuned to 86 Hertz (Hz), to reduce the resultant noise level. AFFECTED VEHICLES MAY REQUIRE THE INSTALLATION OF THE PINION NOSE DAMPER, THE SPRING DAMPERS, OR BOTH. THE INSTALLATION OF EITHER OF THESE DAMPERS IS AT THE DISCRETION OF THE TECHNICIAN FOR BEST RESULTS. Use the following procedures and the appropriate part number listed below. Important: Installation of these dampers will not totally eliminate the boom noise. The boom noise may only be reduced to a more acceptable level. There may be other boom noises, such as body or exhaust, associated with the vehicle and this fix may either diminish or enhance the noise. These other noises should be addressed prior to the correction for the TCC boom dampener being installed. Pinion Nose Damper Installation Procedure Use Damper Kit, Rr. Axle Vib., P/N 15006567, for this procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6979 1. Place the template (1), P/N 15005879, on the bottom surface of the triangular flanged portion of the rear axle. 2. Mark the hole locations. 3. Using a pin punch (1), mark the center location of the holes. 4. Drill a 11 mm (0.44 in) diameter hole in two places. 5. Clean out the holes, including the top and bottom surface of the axle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6980 6. Install the rear axle pinion nose damper (1), P/N 15005880. 7. Install the rear axle pinion nose damper washers (2), P/N 15614758, and the nuts (3), P/N 11516072. Tighten Tighten each nut to 37-53 N.m (27-39 lb ft). 8. Rotate the driveshaft in order to verify that there is no contact between the driveshaft and the pinion nose damper. 9. Test drive the vehicle. Inspect for contact between the driveshaft and the damper. Rear Leaf Spring Damper Installation Procedure Use Damper Kit, Rear Spring Vib., P/N 15042486, for this procedure. 1. Raise the vehicle. Support the rear axle. Refer to the General Information subsection of the appropriate Service Manual for lifting and jacking information. 2. Remove the leaf spring. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 3. Locate the rear spring clip closest to the shackle. This clip maintains the alignment of the rear spring plates # 1 and # 2. Note: Do not damage the top surfaces of the # 1 and # 2 spring plates. Damage may cause premature spring breakage. 4. Insert a wood wedge, no metal or sharp objects, between rear spring plates # 1 and # 2, located forward of the clip. Allow enough clearance to work around. This should maximize the gap between spring plates # 1 and # 2. 5. Grind off or, using an 11 mm (0.44 in) drill bit, drill out the rivet head holding the clip to the # 2 spring plate. 6. Remove the clip and the plastic clip liner from the spring assembly. Discard the spring clip only. 7. Knock out any remaining rivet residue from spring plate # 2. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6981 8. Insert the stud bolt (2), P/N 15042491, from the top of spring plate # 2 (3) so that the bolt head sits into the hole's counter sink. 9. Place the spring clip (1), P/N 15042492, over the stud so that the clip is in a similar position as the original clip removed previously. Do not close the clip at this time. 10. Install the damper (8), P/N 15042487, onto the stud. Install the damper completely onto the stud so that the clip is securely trapped between the # 2 spring plate (bottom) and the damper inner sleeve. Tighten Tighten the damper to 30 N.m (22 lb ft) while holding the stud. 11. Install the jam nut (6), P/N 11508189, onto the stud until the nut is against the inner sleeve of the damper. Tighten Tighten the nut to 30 N.m (22 lb ft). Note: Do not break the clip liner or damage the top surface of the # 1 spring plate. 12. Install the plastic clip liner in the same orientation as when removed. The bolt head may stick up above the top surface of the spring plate. 13. Remove the wood wedge. 14. Using a press or a vise, close the clip to the same position as the removed clip. The maximum width of the installed clip is 91.5 mm (3.6 in) and the maximum height is 46.5 mm (1.8 in). This ensures proper clearance to the body rails. 15. Install the leaf spring onto the vehicle. Refer to the Rear Suspension subsection of the appropriate Service Manual for leaf spring replacement procedures. 16. Repeat steps 2-15 for the other spring. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 00-03-09-001A > Jul > 03 > Drivetrain - Booming Noise at Highway Speeds > Page 6982 Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 6983 Suspension Spring ( Coil / Leaf ): Service and Repair Front Coil Springs Replacement - Tools Required J 23028-01 Coil Spring Remover and Installer Removal Procedure Notice: Use care when handling the coil springs in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the coil springs. 1. Raise the vehicle. Refer to Vehicle Lifting. The lower control arms must hang free. 2. Remove the shock absorber. Caution: Tool J23028-01 should be secured to a suitable jack or personal injury could result. 3. Secure the J23028-01 to a suitable jack. Position the J23028-01 so the tool cradles the inner bushings. 4. Remove the stabilizer shaft link. 5. Raise the jack, under the J23028-01 in order to relieve tension from the lower control arm bolts. 6. Remove the lower control arm bolts and the nuts. Remove the rear bolt and the rear nut first. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 6984 7. Lower the lower control arm by lowering the jack slowly to relieve the tension of the coil spring. Important: Do not apply force on the lower control arm or the lower ball joint in order to remove the coil spring. Proper maneuvering of the coil spring will allow for easy removal. 8. After all compression is removed from the coil spring, remove the coil spring and coil spring insulators from the vehicle. Installation Procedure 1. Install the coil spring and the coil spring insulators to the lower control arm. - The insulators must be in place on the top and bottom of the coil spring. - Install the coil spring with the identification tape towards the lower control arm. - Align the edge of the coil spring with the edge of the insulator. Align the insulator and the drain hole. - The end of the lower spring coil must cover all or part of one inspection drain hole. The other drain hole must be partially exposed or completely uncovered. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Page 6985 Caution: Tool J 23028 01 should be secured to a suitable jack or personal injury could result. 2. Support the lower control arm with J 23028-01. 3. Raise the jack to install the lower control arm so that the bushings match up to the proper holes in the frame. Insure that the coil spring is properly seated in the upper control arm. 4. Install the lower control arm bolts and nuts. - Install the front bolt first, then the rear bolt. - Install the bolts in the proper direction. - Tighten the nuts, but do not torque. 5. Remove the J23028-01 from the vehicle. 6. Install the stabilizer shaft link. 7. Install the shock absorber. Notice: Refer to Fastener Notice in Service Precautions. 8. Lower the vehicle. 8.1. Tighten the lower control arm front nut to 90 Nm (66 ft. lbs.), with the vehicle weight on the wheels. 8.2. Tighten the lower control arm rear nut to 90 Nm (66 ft. lbs.), with the vehicle weight on the wheels. 9. Check the front wheel alignment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 6990 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 6991 Suspension Strut / Shock Absorber: Specifications Shock Absorber Lower Attaching Screws 18 ft. lbs. Shock Absorber Upper Attaching Nut 15 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Page 6992 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the shock absorber mounting nut, the retainer, and the insulator. Hold the shock absorber upper stem in order to keep the stem from turning. A hex is provided on the end of the stem for this purpose. 4. Remove the shock absorber mounting screws. The nuts will remain attached to the lower control arm. 5. Pull the shock absorber out through the hole in the lower control arm. Installation Procedure 1. Install the shock absorber, fully extended, up through the hole in the lower control arm. - The lower retainer and the insulator must be attached to the shock absorber upper stem before positioning the shock absorber. - The shock absorber upper stem will pass through the mounting hole in the upper control arm frame bracket. 2. Install the upper insulator, the retainer, and the shock absorber mounting nut over the shock absorber upper stem. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shock absorber mounting screws through the holes in the lower control arm. 3.1. Make sure the nuts are aligned properly. 3.2. Tighten the shock absorber mounting nut to 20 Nm (15 ft. lbs.), while holding the upper stem of the shock absorber. 3.3. Tighten the shock absorber mounting screws to 25 Nm (18 ft. lbs.). 4. Install the tire and wheel. 5. Lower the vehicle. 6. Dispose of the shock absorber. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) - Tools Required J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 6998 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle - Classify the failure of the wheel bearing with the aid of the illustrations. - Determine the cause of the wheel bearing failure. - Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 6999 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7000 Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7001 Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears The smearing of the metal is due to slippage. Slippage can be caused by the following factors: Poor fits - Lubrication - Overheating - Overloads - Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7002 Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7003 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7004 Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 7005 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Page 7006 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications wheel hub nut 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions Vehicle Lifting: Service Precautions CAUTION: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 7015 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Use only the prescribed lift points when elevating the vehicle. Vehicle Lifting Points 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center 1 - Lower Control Arm; Inboard of the Lower Ball Joint 1 - Lower Control Arm; Inboard of the Lower Ball Joint 2 - Frame; at Second Crossmember 2 - Frame; at Second Crossmember Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 7016 3 - Rear Spring; at Forward Spring Hanger 3 - Rear Spring; at Forward Spring Hanger 4 - Axle; Inboard of Shock Absorber Hanger 4 - Axle; Inboard of Shock Absorber Hanger 5 - Differential; at Center 6 - Front Suspension Crossmember; Center The jack and hoist lift points for the front of the vehicle are located between the front body mounts and the transmission crossmember. The jack and hoist lift points for the rear of the vehicle are located at the front hangers for the rear springs. The front end lift points for the floor jack are at the following locations: * Beneath the lower control arms, inboard from the shock absorber mounts * Beneath the center of the front crossmember The rear end lift points for the floor jack are at the following locations: * Beneath the axle housing, inboard from the shock absorber mounts * Beneath the axle differential Whenever the vehicle is lifted using a jack or a floor jack, observe the following precautions: * Chock the wheels at the end of the vehicle opposite the end being lifted * Use jack stands for support. Place jack stands at the any of the following locations: - Beneath the frame - Beneath the front suspension crossmember - Beneath the axle When removing major components from the vehicle while the vehicle is on a hoist, chain the vehicle frame to the hoist pads in order to prevent tip-off. Jacking and Lifting Notice: When jacking or lifting a vehicle, do not allow the lift pads to contact any of the following parts: * The catalytic converter * The brake lines * The brake cables * The fuel lines * The accelerator cables * The transmission shift cables Lift pad contact may damage the parts. Lift pad contact may cause unsatisfactory vehicle performance. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Mounting Bolts 11 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 7040 Spare Tire: Service and Repair Tire Hoist and Shaft Replacement Removal Procedure 1. Remove the spare tire from the tire carrier. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Remove the pin and retainer from the shaft. 4. Remove the shaft from the hoist. 5. Remove the hoist mounting bolts. 6. Remove the hoist from the rear crossmember. Installation Procedure 1. Install the hoist to the rear crossmember. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hoist mounting bolts and nuts. ^ Tighten the hoist mounting bolts and nuts to 15 Nm (11 ft. lbs.). 3. Install the shaft to the hoist. 4. Install the pin and retainer to the shaft. 5. Lower the vehicle. 6. Install the spare tire to the carrier. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7049 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7050 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7051 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 7056 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7061 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7062 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7063 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7069 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7070 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7071 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 7076 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7081 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7082 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7087 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7088 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7089 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 7094 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7099 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7100 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7101 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7111 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7112 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7113 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 7118 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7123 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7124 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7129 Wheels: Testing and Inspection Wheel Mounting Surface Check Replace any wheels that are bent or dented, or have excessive lateral or radial runout. Wheels with runout greater than specified may cause objectionable vibrations. 1. Use a straight edge 200 - 229 mm (09 inch) long. Place the straight edge on the wheel inboard mounting surface. Try to rock the straightedge up and down within the mounting surface. 2. Repeat this procedure on at least 3-4 different positions on the inboard mounting surface. ^ The outer ring of the mounting surface normally is raised above everything inside the mounting surface. ^ The mounting surface will be raised above the outer ring if the wheel mounting surface has been bent on a tire changer. ^ If you can rock the straight edge, the mounting surface is bent and you must replace the wheel. 3. Inspect the mounting wheel/nut holes for damage caused from over-torquing the wheel/nuts. Inspect for collapsed wheel/nut bosses. Inspect for cracked wheel bosses. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7130 ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Important: ^ Replacement wheels must be equivalent to the original equipment wheels in the following ways: The load capacity - The wheel diameter - The rim width - The wheel offset - The mounting configuration ^ A wheel of the incorrect size or type may affect the following conditions: Wheel and hub-bearing life - Brake cooling - Speedometer/odometer calibration - Vehicle ground clearance - Tire clearance to the body and the chassis 4. Replace the wheel if the wheel is bent. 5. Replace the wheel if the wheel/nut boss area is cracked. Identify steel wheels with a 2 or 3-letter code stamped into the rim near the valve stem. Aluminum wheels have the code, the part number, and the manufacturer identification cast into the back side of the wheel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 inch) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 7133 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrape ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications "Information not supplied by the manufacturer" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Sealed Wheel Bearings Diagnosis (Sealed) - Tools Required J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Tire and Wheel Assembly Runout Measurement - On-Vehicle. Important: If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 inch), replace the wheel bearing/hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7139 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis - Tapered Wheel Bearings Diagnosis (Tapered) Tapered Roller Bearing Diagnosis The following procedure describes how to inspect the wheel bearing for excessive looseness. If excessive wheel bearing looseness is present, adjust the wheel bearings. If excessive looseness is still present after adjustment, inspect the wheel bearings. Consider the following factors when diagnosing the wheel bearing condition: General condition of the following parts during disassembly and inspection: Wheel bearings - Races - Seals - Lubricant - Steering Knuckle - Classify the failure of the wheel bearing with the aid of the illustrations. - Determine the cause of the wheel bearing failure. - Replace the damaged parts. Abrasive Roller Wear The pattern on the races and the rollers is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Abrasive Step Wear The pattern on the roller ends is caused by fine abrasives. 1. Clean all of the parts and the housings. 2. Check the seals and the bearings. 3. Replace leaky seals, rough, or noisy bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7140 Galling The metal smears on the roller ends are due to overheating, lubricant failure, or lubricant overload. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearing. Etching The bearing surfaces appear gray or grayish black in color, with related etching away of material usually at roller spacing. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all of the parts and the housings. 4. Replace the bearings. Bent Cage When a cage is damaged due to improper handling or improper tool usage. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7141 Bent Cage The cage may be damaged due to improper handling or improper tool usage. Replace the bearing. Cage Wear The wear around the outside diameter of the cage and the roller pockets is caused by abrasive material or inefficient lubrication. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Indentations The surface depressions on the race and the rollers are caused by hard particles of foreign matter. 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7142 Frettage The corrosion caused by small relative movement of parts with no lubrication. 1. Check the seals. 2. Check for proper lubrication. 3. Clean all the parts and the housings. 4. Replace the bearings. Smears The smearing of the metal is due to slippage. Slippage can be caused by the following factors: Poor fits - Lubrication - Overheating - Overloads - Handling damage If this condition occurs, perform the following: 1. Check the seals. 2. Check for proper fit. 3. Check for proper lubrication. 4. Clean all the parts and the housings. 5. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7143 Stain Discoloration The discoloration on the bearings is caused by incorrect lubrication or moisture and ranges in color from light brown to black. Reuse the bearing if you can remove the stains with light polishing and there is no evidence of overheating. If this condition occurs, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings, if necessary. Heat Discoloration The heat discoloration on the bearings ranges from faint yellow to dark blue and results from overload or an incorrect lubricant. Excessive heat causes softening of the races or the rollers. In order to check for loss of temper on the races and the rollers, perform a file test. A file drawn over a tempered part will grab and cut the metal and fail the file test. A file drawn over a hard part will glide with no metal cutting. If overheating damage is indicated, perform the following: 1. Check the seals. 2. Clean all the parts and the housings. 3. Replace the bearings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7144 Misalignment The outer race is misaligned due to a foreign object. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Cracked Inner Race The race is cracked due to improper fit, cocking, or poor bearing seats. 1. Clean all the parts and the housings. 2. Ensure the races are properly seated. 3. Replace the bearing. Fatigue Spalling The surface is flaked with metal due to bearing fatigue. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearings Diagnosis - Sealed > Page 7145 Brinelling The surface indentations in the race way are caused by the rollers under impact loading or from vibration while the bearing is not rotating. 1. Clean all the parts and the housings. 2. Replace the bearing. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 7146 Wheel Bearing: Adjustments Front Wheel Bearing Adjustment Important: ^ Adjust the front wheel bearings correctly in order to ensure the front suspension functions properly. ^ The bearings must be a slip fit on the spindle. ^ Lubricate the bearings in order to ensure the bearings will creep. ^ The spindle nut must have a free-running fit on the spindle threads. 1. Raise and suitably support the vehicle with safety stands. Refer to Vehicle Lifting. 2. Remove the wheel cover. 3. Remove the dust cap from the wheel hub. Notice: Refer to Fastener Notice in Service Precautions. 4. Remove the cotter pin. ^ Tighten the wheel hub nut to 16 Nm (12 ft. lbs.), while turning the wheel forward by hand. This will seat the bearings. Important: Do not back the nut off more than 1/2 flat. 5. Adjust the nut to a finger tight position by hand. Then, back the nut off until the hole in the spindle aligns with a slot in the nut. 6. Install a new cotter pin. 6.1. Make sure the cotter pin ends do not interfere with the cap. Bend the ends of the cotter pin against the nut. Cut off any extra pin length. 6.2. Measure the endplay. Proper endplay is 0.0 - 0.13 mm (0.001 - 0.005 inch). 7. Install the dust cap to the wheel hub. 8. Install the wheel cover. 9. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Page 7147 Wheel Bearing: Service and Repair "For information regarding this component please refer to wheel hub service and repair" Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications wheel hub nut 12 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 7160 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 7166 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7167 Wheel Fastener: Specifications Wheel nuts 100 ft. lbs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Stud Replacement Removal Procedure 1. Remove the rotor. 2. Remove the wheel stud. ^ Press the stud out using an arbor press. ^ Do not damage the wheel mounting surface on the wheel hub flange. Installation Procedure 1. Install the stud into the hole in the wheel hub. 1.1. Start the serrated stud into the hole in the wheel hub by tapping lightly with a hammer. 1.2. The stud must be square with the wheel hub before pressing on the arbor press. 2. Install the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7170 Wheel Fastener: Service and Repair Rear Wheel Stud Replacement (Rear Drum Brakes) ^ Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and the wheel. 3. Remove the brake drum. 4. Remove the wheel stud from the axle flange using J 43631. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7171 1. Start the new stud into the axle flange hole by pressing firmly with your hand. 2. Install a washer and thread the lug nut on the wheel stud with the flat side of the lug nut to the vehicle. 3. Tighten the lug nut in order to draw the wheel stud into the rear of the flange. 4. Remove the lug nut and washers from the wheel stud. 5. Install the brake drum. 6. Install the tire and the wheel. 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 7172 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Refrigerant System Capacities - Heating, Ventilation And Air Conditioning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7177 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the accumulator nut (1) from the evaporator. 4. Remove the compressor suction hose (7) from the accumulator. 5. Remove the O-ring seals. 6. Disconnect the electrical connectors. 7. Remove the pressure switch. 8. Remove the accumulator mounting bracket bolt. 9. Remove the accumulator mounting bracket. 10. Remove the accumulator. 11. Install sealing caps if you are not replacing the accumulator. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7178 1. Install the accumulator mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the accumulator mounting bracket bolt. Tighten Tighten the mounting bracket bolt to 4 N.m (35 lb in). 3. Install the pressure switch. 4. Connect the electrical connections. 5. Install new O-ring seals. 6. Install the compressor suction hose (7) to the accumulator. 7. Install the accumulator nut (1) to the evaporator. Tighten Tighten the nut to 27 N.m (20 lb ft). 8. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 10. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7183 Air Temperature Actuator - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7184 Air Door Actuator / Motor: Description and Operation AIR TEMPERATURE ACTUATORS The vehicle operator can determine the temperature of the air by using the air temperature switch. When a desired temperature setting is selected, a voltage divider is used to determine the air temperature door position signal circuit's value. The air temperature door position signal circuit's value is a voltage that is applied to the air temperature actuator. The motor opens the air mixture door to a position to divert sufficient air past the heater core to achieve the desired vehicle temperature. Warm heater air is mixed with cool A/C air at the air mixture door. When the coldest temperature control setting is selected, no warm heater air is mixed with the cool A/C air. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Air Door Actuator / Motor: Service and Repair Air Temperature Actuator REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the engine cover. 3. Remove the screws that retain the actuator to the heater assembly. 4. Disconnect the electrical connector (2). 5. Remove the air temperature actuator from the heater assembly. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 7187 1. Install the air temperature actuator to the heater assembly. 2. Connect the electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the air temperature actuator to the heater assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the engine cover. 5. Install the IP extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 7188 Air Door Actuator / Motor: Service and Repair Defroster Actuator REMOVAL PROCEDURE 1. Remove the right knee bolster. 2. Remove the right cowl trim panel. 3. Disconnect the defrost actuator vacuum hose from the defrost actuator (1). 4. Depress the retaining clip and remove the defrost actuator (1) from the air distribution housing (2). INSTALLATION PROCEDURE 1. Install the defrost actuator (1) to the air distribution housing (2). 2. Connect the defrost actuator vacuum hose to the defrost actuator (1). 3. Install the right cowl trim panel. 4. Install the right knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 7189 Air Door Actuator / Motor: Service and Repair Mode Actuator REMOVAL PROCEDURE 1. Remove the IP assembly from the vehicle. in Instrument Panel, Gages and Console. 2. Remove the mode actuator vacuum hose connector. 3. Slide the actuator off the mounting bracket in order to remove the actuator. 4. Rotate the actuator (2) so that the actuator linkage slips off the post on the mode door linkage. 5. Remove the actuator linkage from the mode door linkage. INSTALLATION PROCEDURE 1. Rotate the actuator so that the actuator linkage slips over the post on the mode door linkage. 2. Install the actuator linkage to the mode door linkage. 3. Slide the actuator (2) onto the mounting bracket in order to install the actuator. Firmly press the actuator into place in order to fully seat the fastener. 4. Install the mode actuator vacuum hose connector. 5. Install the IP assembly to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator > Page 7190 Air Door Actuator / Motor: Service and Repair Recirculation Actuator REMOVAL PROCEDURE 1. Remove the passenger side knee bolster. 2. Remove the right cowl trim panel. 3. Remove the recirculation actuator vacuum (3) connector. 4. Remove the nuts that retain the recirculation actuator. 5. Remove the recirculation actuator from the recirculation door. INSTALLATION PROCEDURE 1. Install the recirculation actuator to the recirculation door. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the nuts that retain the recirculation actuator. Tighten Tighten the nuts to 2 N.m (18 lb in). 3. Install the recirculation actuator vacuum (3) connector. 4. Install the right cowl trim panel. 5. Install the passenger side knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the left floor air outlet. 3. Remove the retaining screw at the IP assembly on the left side of the duct. 4. Remove the retaining clips from the air distributor assembly. 5. Remove the duct from the IP vent extensions. 6. Remove the air distributor duct from the IP. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7195 1. Install the air distributor duct to the IP. 2. Install the air distributor duct to the IP vent extensions. 3. Install the retaining clips to the air distributor assembly. NOTE: Refer to Fastener Notice 4. Install the retaining screws to the IP carrier on the left side of the duct. Tighten Tighten the screws to the IP carrier on the left side of the duct to 2 N.m (18 lb in). 5. Install the left floor air outlet. 6. Install the IP carrier. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7196 Air Duct: Service and Repair Air Outlet Duct Replacement - Auxiliary REMOVAL PROCEDURE 1. Remove the left D- pillar garnish molding. 2. Remove the set screw in the side of the 2 piece duct. 3. Slide the bottom half of the duct up into the top half. 4. Swing the bottom edge of the duct toward the interior of the vehicle. 5. Remove the top edge of the duct clear of the headliner duct. 6. Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE 1. Install the air outlet duct to the vehicle. 2. Install the top edge of the duct into the headliner duct. 3. Swing the bottom edge of the duct into the fourth pillar. 4. Swing the bottom edge of the duct into place over the auxiliary evaporator module. 5. Slide the bottom half of the duct down onto the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Caution and Notices. 6. Tighten the set screw on the side of the duct. Tighten Tighten the set screw on the side of the duct to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7197 7. Install the left fourth pillar garnish molding. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7198 Air Duct: Service and Repair Air Outlet Duct Replacement - Left Defogger REMOVAL PROCEDURE IMPORTANT: Do not remove the instrument panel. 1. Roll the instrument panel down. Refer to IP Carrier Replacement. 2. Remove the duct from the left side floor air outlet. 3. Remove the duct from the left body side window defogger outlet. 4. Remove the duct from the vehicle. INSTALLATION PROCEDURE 1. Install the duct to the vehicle. 2. Install the duct to the left body side window defogger outlet. 3. Install the duct to the left side floor air outlet. 4. Roll the instrument panel up. Refer to IP Carrier Replacement. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7199 Air Duct: Service and Repair Air Outlet Duct Replacement - Left Floor REMOVAL PROCEDURE 1. Remove the instrument panel carrier. 2. Remove the windshield defroster duct. 3. Remove the screws that retain the air outlet duct to the instrument panel carrier. 4. Remove the side window defroster ducts. 5. Remove the air outlet duct from instrument panel. INSTALLATION PROCEDURE 1. Install the air outlet duct to the instrument panel. 2. Install the side window defroster ducts. NOTE: Refer to Fastener Notice 3. Install the screws that retain the floor air outlet duct to the instrument panel carrier. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the windshield defroster duct. 5. Install the instrument panel carrier. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7200 Air Duct: Service and Repair Air Distributor Duct Replacement REMOVAL PROCEDURE 1. Remove the IP assembly. 2. Remove the left floor air outlet. 3. Remove the retaining screw at the IP assembly on the left side of the duct. 4. Remove the retaining clips from the air distributor assembly. 5. Remove the duct from the IP vent extensions. 6. Remove the air distributor duct from the IP. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7201 1. Install the air distributor duct to the IP. 2. Install the air distributor duct to the IP vent extensions. 3. Install the retaining clips to the air distributor assembly. NOTE: Refer to Fastener Notice 4. Install the retaining screws to the IP carrier on the left side of the duct. Tighten Tighten the screws to the IP carrier on the left side of the duct to 2 N.m (18 lb in). 5. Install the left floor air outlet. 6. Install the IP carrier. Air Outlet Duct Replacement - Auxiliary REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7202 1. Remove the left D- pillar garnish molding. 2. Remove the set screw in the side of the 2 piece duct. 3. Slide the bottom half of the duct up into the top half. 4. Swing the bottom edge of the duct toward the interior of the vehicle. 5. Remove the top edge of the duct clear of the headliner duct. 6. Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE 1. Install the air outlet duct to the vehicle. 2. Install the top edge of the duct into the headliner duct. 3. Swing the bottom edge of the duct into the fourth pillar. 4. Swing the bottom edge of the duct into place over the auxiliary evaporator module. 5. Slide the bottom half of the duct down onto the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Caution and Notices. 6. Tighten the set screw on the side of the duct. Tighten Tighten the set screw on the side of the duct to 2 N.m (18 lb in). 7. Install the left fourth pillar garnish molding. Air Outlet Duct Replacement - Left Defogger REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7203 IMPORTANT: Do not remove the instrument panel. 1. Roll the instrument panel down. Refer to IP Carrier Replacement. 2. Remove the duct from the left side floor air outlet. 3. Remove the duct from the left body side window defogger outlet. 4. Remove the duct from the vehicle. INSTALLATION PROCEDURE 1. Install the duct to the vehicle. 2. Install the duct to the left body side window defogger outlet. 3. Install the duct to the left side floor air outlet. 4. Roll the instrument panel up. Refer to IP Carrier Replacement. Air Outlet Duct Replacement - Left Floor REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7204 1. Remove the instrument panel carrier. 2. Remove the windshield defroster duct. 3. Remove the screws that retain the air outlet duct to the instrument panel carrier. 4. Remove the side window defroster ducts. 5. Remove the air outlet duct from instrument panel. INSTALLATION PROCEDURE 1. Install the air outlet duct to the instrument panel. 2. Install the side window defroster ducts. NOTE: Refer to Fastener Notice 3. Install the screws that retain the floor air outlet duct to the instrument panel carrier. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the windshield defroster duct. 5. Install the instrument panel carrier. Air Outlet Duct Replacement - Left Lap REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7205 1. Remove the left knee bolster. 2. Remove the screws that retain the outlet duct. 3. Remove the duct from the air distribution duct. INSTALLATION PROCEDURE 1. Install the duct to the air distribution duct. 2. Install the outlet duct. NOTE: Refer to Fastener Notice 3. Install the screws that retain the outlet duct. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the left knee bolster. Air Outlet Duct Replacement - Right Defogger REMOVAL PROCEDURE IMPORTANT: Do not remove the instrument panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7206 1. Roll the instrument panel down. Refer to IP Carrier Replacement 2. Remove the screws that retain the duct. 3. Remove the duct from the instrument panel. INSTALLATION PROCEDURE 1. Install the duct to the instrument panel. NOTE: Refer to Fastener Notice 2. Install the screws in order to retain the duct. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Roll the instrument panel up. Refer to IP Carrier Replacement. Air Outlet Duct Replacement - Right Lap REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7207 1. Remove the right knee bolster. 2. Remove the air outlet duct from the vehicle. INSTALLATION PROCEDURE 1. Install the air outlet duct to the vehicle. 2. Install the right knee bolster. Deflector Replacement - Auxiliary A/C Outlet - Headliner REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 7208 1. Use a flat blade tool in order to remove the air deflector from the headliner. 2. Remove the air deflector from the vehicle. INSTALLATION PROCEDURE 1. Align the air deflector into the opening in the headliner. 2. Push the air outlet into the headliner until the deflector snaps into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor Air Register: Service and Repair Air Outlet Replacement - Center Floor REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. 4. Remove the front section of the carpet, if equipped. 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7213 1. Install the floor air outlet to the ducts to the rear seat, if equipped. NOTE: Refer to Fastener Notice 2. Install the retaining nuts to the floor outlet duct, if equipped. Tighten Tighten the retaining nuts to 2 N.m (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7214 Air Register: Service and Repair Air Outlet Replacement - Defroster REMOVAL PROCEDURE IMPORTANT: Do not remove the instrument panel. 1. Roll the instrument panel down. Refer to IP Carrier Replacement. 2. Remove the windshield defroster duct grille from the instrument panel. 3. Remove the windshield defroster duct retainers from the instrument panel. 4. Remove the retaining screw on the instrument panel carrier. 5. Remove the windshield defroster duct by rotating the duct downward and away from the instrument panel. INSTALLATION PROCEDURE 1. Install the windshield defroster duct to the instrument panel. NOTE: Refer to Fastener Notice 2. Install the retaining screw to the instrument panel carrier. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Install the windshield defroster duct retainers to the instrument panel. 4. Install the windshield defroster duct grille to the instrument panel. 5. Roll the instrument panel up. Refer to IP Carrier Replacement. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7215 Air Register: Service and Repair Air Outlet Replacement - Rear Floor REMOVAL PROCEDURE 1. Remove the IP extension. 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. 4. Remove the front section of the carpet if equipped. 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat if equipped. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7216 1. Install the floor air outlet to the ducts to the rear seat, if equipped. NOTE: Refer to Fastener Notice 2. Install the retaining nuts to the floor outlet duct, if equipped. Tighten Tighten the retaining nuts to 2 N.m (18 lb in). 3. Install the front section of the carpet if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct to the air distributor. 6. Install the IP extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7217 Air Register: Service and Repair Grille Replacement - Body Side Rear Trim Air Outlet REMOVAL PROCEDURE Pull out ward on the vent in order to remove the vent from the trim panel. INSTALLATION PROCEDURE Press the vent inward in order to install the vent to the trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7218 Air Register: Service and Repair IP Air Outlet Vent Replacement IP AIR OUTLET VENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the right side knee bolster. 2. Remove the screw that retains the air outlet vent to the instrument panel. 3. Lift upward on the instrument panel assist handle. 4. Remove the air outlet vent from the instrument panel. INSTALLATION PROCEDURE 1. Lift upward on the instrument panel assist handle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Center Floor > Page 7219 2. Install the air outlet vent to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the air outlet vent to the instrument panel. Tighten Tighten the screw that retains the air outlet vent to the instrument pane to 2 N.m (18 lb in). 4. Install the right side knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Air Temperature Sensor Resistance Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7223 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7224 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on the M/L van is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). NOTE: Refer to Fastener Notice 2. Install the screws to the blower motor resistor assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7267 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7268 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7269 Blower Motor Resistor: Diagrams Blower Motor Resistor Assembly - HVAC Systems - Manual Blower Motor Resistor - A/C Auxiliary - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 7270 Blower Motor Resistor - Heater Auxiliary - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (C60) Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement (C60) REMOVAL PROCEDURE IMPORTANT: The blower motor relay is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). NOTE: Refer to Fastener Notice 2. Install the screws to the blower motor resistor assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connectors. 4. Install the windshield washers and the coolant reservoir. 5. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (C60) > Page 7273 Blower Motor Resistor: Service and Repair Blower Motor Resistor Assembly Replacement (YG6) REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly. INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly. NOTE: Refer to Fastener Notice 2. Install the screws to the blower motor resistor assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Connect the electrical connectors. 4. Install the windshield washers and the coolant reservoir. 5. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (C60) > Page 7274 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Auxiliary Air Conditioning REMOVAL PROCEDURE 1. Remove the left body side trim panel. 2. Remove the electrical connector. 3. Remove the screws that retain the resistor (4) to the case. 4. Remove the auxiliary A/C blower motor resistor assembly from the case. INSTALLATION PROCEDURE 1. Install the auxiliary A/C blower motor resistor assembly into the case. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the screws that retain the resistor to the case. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the electrical connector. 4. Install the left body side rear trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Assembly Replacement (C60) > Page 7275 Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement - Heater Auxiliary REMOVAL PROCEDURE 1. Remove the left body side trim panel. 2. Remove the electrical connector. 3. Remove the screws from the auxiliary heater blower motor resistor assembly. 4. Remove the auxiliary heater blower motor resistor assembly (1) from the heater case. INSTALLATION PROCEDURE 1. Install the auxiliary heater blower motor resistor assembly (1) into the heater case. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the auxiliary heater blower motor resistor assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the electrical connector. 4. Install the left body side rear trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7279 Blower Motor Switch: Diagrams Blower Motor Switch - A/C Auxiliary - HVAC Systems - Manual Blower Motor Switch - Heater Auxiliary Part 1 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7280 Blower Motor Switch - Heater Auxiliary Part 2 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary Air Conditioning REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7283 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7284 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7285 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Compressor Clutch Gap Compressor Clutch Gap Gap 0.50 - 0.76 mm (0.020 - 0.030 in) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7290 A/C Compressor Clutch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Removal TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 33023-A Puller Pilot ^ J 41552 Pulley Puller ^ J 29886 Driver Handle ^ J 9398-A Bearing Remover 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: ^ The pulley rotor (1) ^ The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7295 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 7.1. Remove the forcing screw from the J 41552. 7.2. Ensure that the puller tangs still engage in the rotor slots. 7.3. Invert the assembly onto a solid flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. 8. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7296 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Install TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 33023-A Puller Pilot ^ J 41552 Pulley Puller ^ J 29886 Driver Handle ^ J 21352-A Support Block ^ J 9481-A Bearing Installer ^ J 33019 Bearing Staking Tool ^ J 33017 Pulley and Bearing Assembly Installer ^ J 8433-1 Puller Bar ^ J 9398-A Bearing Remover ^ J 34992 Holding Fixture NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. 2. Use the following tools in order to align the new bearing squarely with the hub bore: ^ The J 41552 ^ The J 9481-A ^ The J 29886 3. Drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing, if used as shown. 4. Place the J 33019 in the hub bore. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7297 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. IMPORTANT: Use care in order to prevent personal injury when striking the staking pin with a hammer. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. IMPORTANT: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7298 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots. 12. Thread the through bolts into the J 34992. Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J 8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 14. Use the snap ring pliers in order to install the following components: 14.1. The pulley rotor (1) 14.2. The retaining ring (2) 14.3. Install the clutch plate and hub assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7299 Compressor Clutch Bearing: Service and Repair Clutch Rotor and/or Bearing Replacement (HT6/HD6/HU6) REMOVAL PROCEDURE Tools Required ^ J 6083 External Snap Ring Pliers ^ J 33023-A Puller Pilot ^ J 41552 Compressor Pulley Puller ^ J 29886 Driver Handle ^ J 21352-A Support Block ^ J 9481-A Bearing Installer ^ J 33019 Pulley Bearing Staking Tool ^ J 33017 Pulley and Bearing Installer ^ J 8433-1 Puller Bar ^ J 9398-A Rotor Bearing Remover ^ J 34992 Compressor Holding Fixture 1. Remove the A/C compressor. 2. Remove the clutch plate and hub assembly. 3. Use the J 6083 in order to remove the following components: ^ The pulley rotor (1) ^ The bearing assembly retaining ring (2) 4. Install the J 33023-A to the front head. 5. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7300 6. Turn the J 41552 clockwise in the slots in the rotor. 7. Perform the following steps in order to remove the pulley rotor and bearing assembly: 7.1. Hold the J 41552 in position. 7.2. Tighten the puller screw against the puller guide. 7.3. Remove the pulley rotor and bearing assembly. 8. Use the following procedure to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: 8.1. Remove the forcing screw from the J 41552. 8.2. Ensure that the puller tangs still engage in the rotor slots. 8.3. Invert the assembly onto a solid flat surface or blocks. NOTE: It is not necessary to remove the staking in front of the bearing to remove the bearing, however, it will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged. 9. Use the J 9398-A and the J 29886 in order to drive the bearing out of the rotor hub. INSTALLATION PROCEDURE NOTE: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent. 1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during bearing installation. 2. Use the following tools in order to align the new bearing squarely with the hub bore: ^ The J 41552 ^ The J 9481-A ^ The J 29886 3. Drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing, if used as shown. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7301 4. Place the J 33019 in the hub bore. 5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under the staking pin location. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin. IMPORTANT: Use care in order to prevent personal injury when striking the staking pin with a hammer. 6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing. IMPORTANT: Noisy bearing operation and reduced bearing life may result if the outer bearing race is deformed while staking. Ensure that the stake metal does not contact the outer race of the bearing. 7. Stake 3 locations on the bearing race 120 degrees apart as shown. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Bearing > Component Information > Service and Repair > Clutch Rotor and/or Bearing Removal > Page 7302 8. With the compressor mounted on the J 34992, position the pulley rotor (1) and the bearing assembly on the front head. 9. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 10. Position the J 8433-1 on the J 33023-A. 11. Assemble the 2 through bolts and the washers through the puller bar slots 12. Thread the through bolts into the J 34992. Ensure that the thread of the through bolts engage the full thickness of the J 34992. 13. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J 33017 slips off direct in-line contact with the inner race of the bearing, perform the following steps: 13.1. Loosen the J 8433-3. 13.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 14. Use the snap ring pliers in order to install the following components: 14.1. The pulley rotor (1) 14.2. The retaining ring (2) 14.3. Install the clutch plate and hub assembly. 14.4. Install the A/C compressor. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Removal TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 33023-A Puller Pilot ^ J 41552 Pulley Puller ^ J 8433-1 Puller Bar ^ J 33025 Clutch Coil Puller Legs ^ J 8433-3 Forcing Screw 1. Remove the clutch plate and hub assembly. 2. Use the J 6083 in order to remove the following components: ^ The pulley rotor (1) ^ The bearing assembly retaining ring (2) 3. Install the J 33023-A to the front head. 4. Install the J 41552 down into the inner circle of slots (1) in the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7307 5. Turn the J 41552 clockwise in the slots in the rotor. 6. Perform the following steps in order to remove the pulley rotor and bearing assembly: 6.1. Hold the J 41552 in position. 6.2. Tighten the puller screw against the puller guide. 6.3. Remove the pulley rotor and bearing assembly. 7. Mark the clutch coil terminal location (1) on the compressor front head. Refer to Clutch Rotor and/or Bearing Removal. 8. Install the J 33023-A on the front head of the compressor. 9. Install the J 8433-1 and the J 33025. 10. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7308 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Install TOOLS REQUIRED ^ J 33024 Clutch Coil Installer Adapter ^ J 8433-1 Puller Bar ^ J 34992 Holding Fixture ^ J 33017 Pulley and Bearing Assembly Installer ^ J 33023-A Puller Pilot ^ J 6083 Snap Ring Pliers 1. Place the clutch coil assembly (1) on the front head. Position the terminals at the marked location. 2. Place the J 33024 over the internal opening of the clutch coil housing. 3. Align the J 33024 with the compressor front head. 4. Center the J 8433-1 in the counter-sunk center hole of the J 33024. 5. Install the 2 through bolts and washers through the crossbar slots. 6. Thread the bolts into the J 34992 in order to achieve full fixture thickness. 7. Turn the center forcing screw of the J 8433-1 in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024 remain aligned during installation. 8. When the coil is fully seated on the front head, use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7309 9. Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm (0.01-0.015 in) deep. 10. With the compressor mounted to the J 34992, position the pulley rotor (1) and bearing assembly on the front head. 11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 12. Position the J 8433-1 on the J 33023-A. 13. Assemble the 2 through bolts and washers through the puller bar slots. 14. Thread the bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 15. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. If the J 33017 slips off direct in-line contact with the inner race and bearing, perform the following steps: 15.1. Loosen the J 8433-3. 15.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7310 16. Use the J 6083 in order to install the following components: ^ The pulley rotor (1) ^ The retainer ring (2) 17. Install the clutch plate and hub assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7311 Compressor Clutch Coil: Service and Repair Compressor Clutch Coil Replacement TOOLS REQUIRED ^ J 6083 Snap Ring Pliers ^ J 8433-1 Puller Bar ^ J 8433-3 Forcing Screw ^ J 33017 Pulley and Bearing Assembly Installer ^ J 33023-A Puller Pilot ^ J 33024 Clutch Coil Installer Adapter ^ J 33025 Clutch Coil Puller Legs ^ J 39400-A Halogen Leak Detector ^ J 34992 Holding Fixture ^ J 41552 Pulley Puller REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor from the vehicle. 3. Remove the clutch plate and hub assembly. 4. Use the J 6083 in order to remove the following components: ^ The pulley rotor ^ The bearing assembly retaining ring 5. Install the J 33023-A to the front head. 6. Install the J 41552 down into the inner circle of slots (1) in the rotor. 7. Turn the J 41552 clockwise in the slots in the rotor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7312 8. Perform the following steps in order to remove the pulley rotor and bearing assembly: 8.1. Hold the J 41552 in position. 8.2. Tighten the puller screw against the puller guide. 8.3. Remove the pulley rotor and bearing assembly. 9. Mark the clutch coil terminal location (1) on the compressor front head. 10. Install the J 33023-A on the front head of the compressor. 11. Install the J 8433-1 and the J 33025. 12. Tighten the J 8433-3 against the puller pilot in order to remove the clutch coil (2). 13. Remove the clutch coil from the compressor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7313 1. Install the clutch coil to the compressor. 2. Place the clutch coil assembly on the front head. Position the terminals (1) at the marked location. 3. Place the J 33024 over the internal opening of the clutch coil housing (1). 4. Align the J 33024 with the compressor front head. 5. Center the J 8433-1 in the counter-sunk center hole of the J 33024. 6. Install the two bolts and washers through the crossbar slots. 7. Thread the bolts into the J 34992 in order to achieve full fixture thickness. 8. Turn the center forcing screw of the J 8433-1 in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024 remain aligned during installation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7314 9. When the coil is fully seated on the front head, mark the front head at 3 places 120 degrees apart. IMPORTANT: Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm ( 0.01-0.015 in) deep. 10. Use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Compressor Clutch Coil Removal > Page 7315 11. With the compressor mounted to the J 34992, position the pulley rotor (1) and bearing assembly on the front head. 12. Position the J 33017 and the J 33023-A directly over the inner race of the bearing. 13. Position the J 8433-1 on the J 33023-A. 14. Assemble the two bolts and washers through the puller bar slots. 15. Thread the bolts into the J 34992. Ensure that the thread of the through bolts engages the full thickness of the J 34992. 16. Tighten the center screw in the J 8433-1 in order to force the pulley rotor and bearing assembly onto the compressor front head. 17. If the J 33017 slips off direct in-line contact with the inner race and bearing, perform the following steps: 17.1. Loosen the J 8433-3. 17.2. Realign the installer and the pilot in order to ensure that the J 33017 properly clears the front head. 18. Use the J 6083 in order to install the following components: ^ The pulley rotor (1) ^ The retainer ring (2) 19. Install the clutch plate and hub assembly. 20. Install the compressor to the vehicle. 21. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 22. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal Compressor Clutch Hub: Service and Repair Compressor Clutch Plate and Hub Assembly Removal TOOLS REQUIRED ^ J 34992 Compressor Holding Fixture ^ J 33013-B Hub and Drive Plate Remover/Installer 1. Clamp the J 34992 in a vise. 2. Use thumb screws in order to attach the compressor to the holding fixture. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 3. Ensure that the center screw forces the tip to thrust against the end of the shaft. 4. Thread the J 33013-B into the hub. 5. While holding the body of J 33013-B of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly (1). 6. Remove the shaft key. Retain the shaft key for reassembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7320 Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Install TOOLS REQUIRED J 33013-B Hub and Drive Plate Remover/Installer 1. Install the shaft key (4) into the hub key groove. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 2. Clean the following components: ^ The clutch plate ^ The clutch rotor (2) 3. Align the shaft key (4) with the shaft keyway (3). 4. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 5. Remove the forcing tip on the J 33013-B. 6. Reverse the body direction on the center screw. 7. Install the J 33013-B with the bearing. 8. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 9. Hold the center screw with a wrench. 10. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 11. Tighten the body several turns. 12. Remove the installer. Ensure that the shaft key remains in place in the keyway. 13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap (2) between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76 mm (0.20-0.30 in). 14. Remove the J 33013-B. 15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7321 16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7322 Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement TOOLS REQUIRED ^ J 33013-B Hub and Drive Plate Installer ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the compressor from the vehicle. 3. Use the Compressor Holding Fixture HD-6 tool in order to hold the compressor in a vise. 4. Use both thumb screws in order to attach the compressor to the holding fixture. 5. Install the compressor into a vise. 6. Remove the shaft protector from the clutch hub shaft. NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the compressor may result. The forcing tip on the J 33013-B remover/installer center screw must be flat or the end of the shaft/axial plate assembly will be damaged. 7. Ensure that the center screw forces the tip to thrust against the end of the shaft. 8. Thread the J 33013-B into the hub. 9. While holding the body of J 33013-8 of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly. 10. Remove the shaft key. Retain the shaft key for reassembly. 11. Remove the old clutch plate and hub assembly from the compressor. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7323 1. Install the shaft key (4) into the hub key groove. 2. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway (3). The shaft key curves slightly in order to provide an interference fit in the hub key groove. 3. Clean the following components: ^ The clutch plate ^ The clutch rotor (2) 4. Align the shaft key (4) with the shaft keyway (3). 5. Place the clutch plate and the hub assembly (1) onto the compressor shaft. 6. Install the forcing tip on the J 33013-B. 7. Reverse the body direction on the center screw. 8. Install the J 33013-B with the bearing. 9. Back off the body of the J 33013-B as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft. 10. Hold the center screw with a wrench. 11. Tighten the hex portion of the J 33013-B body in order to press the hub onto the shaft. 12. Tighten the body several turns. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Compressor Clutch Plate and Hub Assembly Removal > Page 7324 13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap between frictional surfaces of the clutch plate and clutch rotor measures within 3.81-0.51 mm (0.15-0.20 in). 14. Check the clutch plate and hub assembly in three places for clearance. 15. Remove the installer. Ensure that the shaft key remains in place in the keyway. 16. Remove the J 33013-B. 17. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub. 18. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate. 19. Install the shaft protector to the clutch hub shaft. 20. Remove both thumb screws from the compressor holding fixture Compressor Holding Fixture HD-6 Compressor Holding Fixture HD-6. 21. Remove the Compressor Holding Fixture HD-6 Compressor Holding Fixture HD-6 tool from the vise. 22. Install the compressor to the vehicle. 23. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 24. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7328 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Refrigerant System Capacities - Heating, Ventilation And Air Conditioning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7332 Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the grille. 4. Remove the compressor hose assembly from the condenser. 5. Remove the evaporator tube from the condenser. 6. Remove the center support bracket. 7. Remove the bolts that retain the condenser to the radiator. 8. Remove the condenser. INSTALLATION PROCEDURE 1. Install the condenser. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts that retain the condenser to the radiator. Tighten Tighten the bolts that retain the condenser to the radiator to 6 N.m (53 lb in). 3. Install the center support bracket. 4. Install the evaporator tube to the condenser. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7333 5. Install the compressor hose assembly to the condenser. Tighten Tighten the bolts to 28 N.m (21 lb ft). 6. Install the grille. 7. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 8. Leak test the fittings of the component using the J 39400-A. 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7338 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 HVAC Control Assembly C1 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 > Page 7341 Control Assembly: Diagrams HVAC Control Assembly C2 HVAC Control Assembly C2 Part 1 - HVAC Systems - Manual HVAC Control Assembly C2 Part 2 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 > Page 7342 HVAC Control Assembly C3 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7343 Control Assembly: Service and Repair HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the IP cluster trim plate. 2. Remove the retaining screw from the left edge of the HVAC control assembly. 3. Pivot the HVAC control assembly from the IP. 4. Remove the HVAC control assembly from the IP in order to access the vacuum and the electrical connectors. 5. Disconnect the following items from the HVAC control assembly: ^ The electrical connectors ^ The vacuum connectors INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7344 1. Connect the following items to the HVAC control assembly: ^ The vacuum connectors ^ The electrical connectors 2. Align the tab on the HVAC control assembly with the slot in the IP. 3. Install the HVAC control assembly to the IP. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screw to the HVAC control assembly. Tighten Tighten the screw to 2 N.m (18 lb in). 5. Install the IP cluster trim plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure ^ For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). ^ For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the A/C seal from the A/C refrigerant component. 3. Inspect the A/C seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7350 IMPORTANT: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. ^ For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. ^ For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7351 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. 5. The washer must completely bottom against the surface of the fitting. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7352 IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 6. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7361 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7362 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7368 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7369 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7370 Refrigerant System Capacities - Heating, Ventilation And Air Conditioning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary Evaporator Core: Service and Repair Evaporator Core - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the left body side rear trim panel. 3. Remove the air outlet duct assembly. 4. Disconnect the electrical connectors. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Remove the retaining nut in order to remove the auxiliary evaporator rear tube assembly from the core. 7. Lower the vehicle. 8. Remove the bolts that retain the case to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7373 9. Remove the auxiliary evaporator module assembly from the vehicle. 10. Remove the screws from the case. 11. Separate the case halves. 12. Remove the evaporator core seal. 13. Remove the core from the case. 14. Inspect the gaskets and the seals for damage. 15. Replace the gaskets and the seals. INSTALLATION PROCEDURE 1. Install the evaporator core into the case. 2. Install the evaporator core seal. 3. Reassemble the case halves. 4. Install the auxiliary evaporator module assembly to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7374 5. Install the bolts that retain the case to the vehicle. Tighten Tighten the bolts to 10 N.m (86 lb in). 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 7. Install the auxiliary evaporator underbody rear tube assembly to the core with the retaining nut. Tighten Tighten the nut to 10 N.m (86 lb in). 8. Lower the vehicle. 9. Connect the electrical connectors. 10. Install the air outlet duct assembly. 11. Install the left body side rear trim panel. 12. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 13. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7375 Evaporator Core: Service and Repair Evaporator Core Replacement TOOLS REQUIRED J 39400-A REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging 3. Remove the coolant recovery reservoir. 4. Disconnect the electrical connectors. 5. Remove the compressor hose assembly from the accumulator. 6. Remove the bypass valve bracket from the outer case. 7. Remove the evaporator tube from the accumulator. 8. Remove the relay bracket. 9. Remove the evaporator tube from the evaporator. Refer to the appropriate procedure: ^ Evaporator Tube Replacement ^ Evaporator Tube Replacement - Auxiliary Front 10. Remove the screws from the outer evaporator case. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core - Auxiliary > Page 7376 11. Remove the outer case from the module. 12. Remove the screws in order to split the evaporator module in half. 13. Remove the inner case from the module. 14. Remove the evaporator core. INSTALLATION PROCEDURE 1. Install the evaporator core. NOTE: Refer to Fastener Notice. 2. Install the inner case to the evaporator module. Tighten Tighten the screws to the evaporator case to 6 N.m (53 lb in) 3. Install the outer case to the evaporator module. Tighten Tighten the screws to the evaporator case to 6 N.m (53 lb in) 4. Install the evaporator tube to the evaporator. ^ Evaporator Tube Replacement ^ Evaporator Tube Replacement - Auxiliary Front 5. Install the bypass valve bracket to the outer case. 6. Install the evaporator to the accumulator. 7. Install the compressor hose assembly to the accumulator. 8. Install the relay bracket. 9. Connect the electrical connectors. 10. Install the coolant recovery reservoir. 11. Refill the engine coolant. Refer to Draining and Filling Cooling System 12. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging 13. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED ^ J 26549-E Orifice Tube Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube from the evaporator. 4. Remove the O-ring seal. 5. Use the J 26549-E in order to remove the orifice tube. 6. If you have difficulty removing a restricted or plugged expansion (orifice) tube, use the following procedure. 6.1. Remove as much of any impacted residue as possible. NOTE: If the system has a pressure switch near the expansion (orifice) tube location, it should be removed prior to heating the pipe to avoid damage to switch. 6.2. Carefully apply heat with a heat gun (hair dryer, epoxy dryer, or equivalent) approximately 7 mm (0.25 in) from the dimples on the inlet pipe. DO NOT overheat the pipe. 6.3. While applying heat, use the J 26549-E in order to remove the orifice tube. 6.4. Use a turning motion along with a push-pull motion in order to loosen the impacted expansion (orifice) tube. 6.5. Remove the expansion (orifice) tube. INSTALLATION PROCEDURE IMPORTANT: Install the shorter screen end of the expansion (orifice) tube into the evaporator first. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 7380 1. Use the J 26549-E in order to install the expansion (orifice) tube. 2. Install the new O-ring seal. NOTE: Refer to Fastener Notice in Caution and Notices. 3. Install the evaporator tube to the evaporator. Tighten Tighten the evaporator tube nut to 28 N.m (20 lb ft). 4. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 5. Leak test the fittings of the component using the J 39400-A. 6. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT - AUXILIARY TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the evaporator core. 2. Gently remove the sealer packed around the thermostatic expansion valve (TXV). IMPORTANT: Note the mounting location and the orientation of the capillary tube on the evaporator core. 3. Remove the clip that retains the capillary tube to the evaporator core. 4. Remove the nuts that retain the TXV to the evaporator core. 5. Remove the TXV from the core. INSTALLATION PROCEDURE 1. Install the TXV to the core. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the nuts that retain the TXV to the evaporator core. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7384 Tighten Tighten the nuts that retain the TXV to the evaporator core to 5 N.m (44 lb in). IMPORTANT: Install the retaining clip and the capillary tube in the location and the orientation that was noted during disassembly. 3. Install the capillary tube and the retaining clip to the evaporator core. 4. Pack the sealer around the TXV as found during disassembly. 5. Install the evaporator core. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Diagrams Coolant Bypass Valve Solenoid - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Front) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. Refer to Draining and Filling Cooling System 4. Remove the heater inlet pipe (5) and the outlet pipe (6) from the bypass valves (4). 5. Remove the bolt (3) that retains the valve (4) to the heater assembly. 6. Remove the bypass valve (4) from the heater assembly. INSTALLATION PROCEDURE 1. Install the bypass valve (4) to the heater assembly. NOTE: Refer to Fastener Notice 2. Install the bolt (3) that retains the valve (4) to the heater assembly. Tighten Tighten the bolt to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 7390 3. Install the heater inlet pipe (5) and the outlet pipe (6) to the bypass valves. 4. Refill the cooling system. Refer to Draining and Filling Cooling System 5. Install the upper fan shroud. 6. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 7391 Heater Control Valve: Service and Repair Hot Water Bypass Valve Replacement (Rear) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Drain the engine coolant. Refer to Draining and Filling Cooling System 4. Disconnect the electrical connector from the valve. 5. Disconnect the vacuum hose from the valve. 6. Remove the hose clamps from the outlet pipe (8) and from the inlet pipe (4). 7. Remove the bolt (3) that retains the valve to the heater assembly. 8. Remove the bypass valve (5) from the heater assembly. 9. Remove the heater hoses from the engine to the hot water bypass valve. INSTALLATION PROCEDURE 1. Install the heater hoses to the engine to the hot water bypass valve. 2. Install the bypass valve (5) to the heater assembly. NOTE: Refer to Fastener Notice. 3. Install the bolt (3) that retains the valve (5) to the heater assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair > Hot Water Bypass Valve Replacement (Front) > Page 7392 Tighten Tighten the bolt to 4 N.m (35 lb in). 4. Install the heater inlet pipe (4) and the outlet pipe to the bypass valves. 5. Connect the vacuum hose to the valve. 6. Connect the electrical connector to the valve. 7. Refill the cooling system. Refer to Draining and Filling Cooling System 8. Install the upper fan shroud. 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7397 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7398 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CASE REPLACEMENT (C60) REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Remove the heater hoses from the heater core. 4. Remove the evaporator case from the vehicle. 5. Remove the heater case retaining nuts (2) from the engine compartment. 6. Roll out the instrument panel. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. 7. Disconnect the electrical connectors. 8. Disconnect the vacuum lines. 9. Remove the heater case (5) from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7401 1. Install the heater case (5) to the vehicle. 2. Connect the vacuum lines. 3. Connect the electrical connectors. 4. Roll the instrument panel upward. Refer to IP Carrier Replacement in Instrument Panel, Gages and Console. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the heater case retaining nuts (2) to the engine compartment. Tighten Tighten the nuts to 6 N.m (53 lb in). 6. Install the evaporator casing to the vehicle. 7. Connect the heater hoses from the heater core. 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7402 Heater Core: Service and Repair Heater Core Replacement REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the heater hoses. 3. Remove the screws (9) that retain the cover to the heater case assembly. 4. Remove the straps (8) that retain the heater core to the heater case assembly. 5. Remove the heater core (7) from the vehicle. INSTALLATION PROCEDURE 1. Install the heater core to the vehicle. 2. Install the straps that retain the heater core to the heater case assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the heater core to the heater case assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the heater hoses. 5. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7403 Heater Core: Service and Repair Heater Core Replacement - Auxiliary REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the body side front lower trim panel. 3. Remove the clamps from the auxiliary heater pipes. 4. Disconnect the auxiliary heater pipes from the auxiliary heater module. 5. Remove the screws and the band clamp from the right side of the heater core. 6. Remove the screw and the band clamp from the left side of the heater core. IMPORTANT: Before removing the auxiliary heater module from the vehicle, be sure to place a protective cover on the floor in order to prevent coolant from leaking onto the carpet. 7. Remove the heater core from the heater core case. 8. Remove the seals from the heater core. INSTALLATION PROCEDURE 1. Install the seals to the heater core. 2. Install the heater core into the heater core case. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw and the band clamp to the left side of the heater core. Tighten Tighten the screws and the band clamp to 2 N.m (18 lb in). 4. Install the screws and the band clamp to the right side of the heater core. Tighten Tighten the screw and the band clamp to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7404 5. Connect the auxiliary heater pipes from the auxiliary heater module. 6. Install the clamps to the auxiliary heater pipes. 7. Install the body side front lower trim panel. 8. Refill the system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Front REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the front pipes (5) from the rear pipes. 4. Remove the bolts (3) that retain the front pipes (5) to the body. 5. Remove the clips (4) that retain the front pipes (5) to the body. 6. Remove the auxiliary heater front pipes (5) from the heater hoses (1). 7. Remove the auxiliary heater front pipes (5). INSTALLATION PROCEDURE 1. Install the auxiliary heater front pipes (5). 2. Connect the auxiliary heater front pipes (5) to the heater hoses (1). 3. Install the front pipe retaining clips (4) that retains the front pipes (5) to the body. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolts (3) that retain the front pipes (5) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Connect the auxiliary heater front pipes (5) to the rear pipes. 6. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7409 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7410 Heater Hose: Service and Repair Heater Pipe Replacement - Auxiliary Rear REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Disconnect the auxiliary heater rear pipes from the heater core inlet and outlet tubes. 4. Disconnect the auxiliary heater rear pipes from the front pipes. 5. Remove the pipe retainers from the body. 6. Remove the auxiliary heater rear pipes. INSTALLATION PROCEDURE 1. Install the auxiliary heater rear pipes. 2. Install the pipe retainers to the body. 3. Connect the auxiliary heater rear pipes to the front pipes. 4. Connect the rear pipes to the auxiliary heater core inlet and outlet tubes. 5. Refill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7411 Heater Hose: Service and Repair Heater Hose Replacement - Inlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the inlet (3) hose from the heater core. 7. Disconnect the inlet (3) hose from the water valve. INSTALLATION PROCEDURE 1. Connect the inlet (3) hose to the water valve. 2. Connect the inlet (3) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7412 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fittings component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7413 Heater Hose: Service and Repair Heater Hose Replacement - Outlet TOOLS REQUIRED ^ J 38185 Hose Clamp Pliers ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the windshield washers and the coolant reservoir from the vehicle. 4. Remove the heater hose support bolt (5) from the clamp (4). 5. Remove the clamp from the heater hose. 6. Disconnect the outlet (2) hoses from the heater core. 7. Disconnect the outlet (2) hoses from the water valve. INSTALLATION PROCEDURE 1. Connect the outlet (2) hose to the water valve. 2. Connect the outlet (2) hose to the heating core. 3. Install the clamp to the heater hose. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the heater hose support bolt (5) to the heater hose clamp (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Pipe Replacement - Auxiliary Front > Page 7414 Tighten Tighten the bolt to 4 N.m (35 lb in). 5. Use the J 38185 6. Install the windshield washers and the coolant reservoir. 7. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 8. Leak test the fitting component using the J 39400-A 9. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Removal TOOLS REQUIRED J 34992 Compressor Holding Fixture 1. Install the compressor onto the J 34992. 2. Remove the pressure relief valve (5) from the rear head of the compressor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7419 High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Install TOOLS REQUIRED J 43600 Refrigerant Station 1. Clean the valve seat area on the rear head. 2. Lubricate the O-ring of the new pressure relief valve (5) and the O-ring assembly using new 525 viscosity refrigerant oil. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the new pressure relief valve (5). Tighten Tighten the new valve to 9.0 N.m (6.1 lb ft). 4. Evacuate and recharge the system using the J 39500-B. 5. Leak test the system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7420 High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Replacement TOOL REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Clean the valve seat area on the rear head. 4. Remove the pressure relief valve (1). INSTALLATION PROCEDURE 1. Lubricate the O-ring of the new pressure relief valve (1) using new 525 viscosity refrigerant oil. NOTE: Refer to Component Fastener Tightening Notice in Service Precautions. 2. Install the pressure relief valve (1). Tighten The pressure relief valve to 9 N.m (80 lb in). 3. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Compressor Pressure Relief Valve Removal > Page 7421 4. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 5. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Remove the compressor hose assembly bolt (2) from the compressor. 8. Remove the old sealing washers from the compressor. 9. Remove the hose clamp bracket nut (3) from the engine stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7426 10. Remove the compressor hose assembly nut (6) from the condenser. 11. Remove the compressor hose assembly nut (1) from the accumulator. 12. Remove the bolt from the transmission filler tube to the oil indicator tube. 13. Remove transmission filler tube from the throttle cable bracket. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections on the vehicle. INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolt to the transmission filler tube to the oil indicator tube. Tighten Tighten the bolt to the oil indicator tube to 12 N.m (106 lb in). 5. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7427 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the compressor hose assembly seals. 9. Install the sealing washers. 10. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). 11. Install the engine cover. 12. Install the grille. 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. 15. Install the air cleaner. 16. Connect the IAT sensor. 17. Connect the MAF sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7428 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7429 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7430 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7431 Hose/Line HVAC: Service and Repair Compressor/Condenser Hose Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Raise vehicle. Refer to Lifting and Jacking the Vehicle. 8. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 9. Lower vehicle. 10. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7432 11. Remove the hose clamp bracket nut (3) from the engine stud. 12. Remove the compressor hose assembly bolt from the compressor. 13. Remove the sealing washers from the compressor. 14. Remove the compressor hose assembly nut (6) from the condenser. 15. Remove the compressor hose assembly nut (1) from the accumulator. 16. Remove the compressor hose assembly from the vehicle. 17. Cap or plug all open connections. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7433 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the compressor hose assembly nut (1) to the accumulator to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the compressor hose assembly nut to the condenser to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7434 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7435 9. Raise the vehicle. 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. 17. Connect the IAT sensor. 18. Connect the MAF sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7436 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube (2) from the evaporator. 4. Remove the O-ring seal. 5. Remove the grille. 6. Remove the evaporator tube (2) from the condenser (4). 7. Remove the O-ring seal. 8. Remove the evaporator tube from the auxiliary A/C evaporator underbody front tube assembly (if equipped). INSTALLATION PROCEDURE 1. Install the NEW O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). NOTE: Refer to Fastener Notice in Caution and Notices. 3. Tighten the evaporator tube nut (3) to the condenser (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7437 Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Install the evaporator tube to the auxiliary A/C evaporator underbody front tube assembly (if equipped). Tighten Tighten the evaporator tube nut to the auxiliary A/C evaporator to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7438 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Remove the compressor hose assembly bolt (2) from the compressor. 8. Remove the old sealing washers from the compressor. 9. Remove the hose clamp bracket nut (3) from the engine stud. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7439 10. Remove the compressor hose assembly nut (6) from the condenser. 11. Remove the compressor hose assembly nut (1) from the accumulator. 12. Remove the bolt from the transmission filler tube to the oil indicator tube. 13. Remove transmission filler tube from the throttle cable bracket. 14. Remove the compressor hose assembly from the vehicle. 15. Cap or plug all open connections on the vehicle. INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. 3. Install transmission filler tube to the throttle cable bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the bolt to the transmission filler tube to the oil indicator tube. Tighten Tighten the bolt to the oil indicator tube to 12 N.m (106 lb in). 5. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the nut to 48 N.m (35 lb ft). 6. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the nut to 28 N.m (21 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7440 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the compressor hose assembly seals. 9. Install the sealing washers. 10. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). 11. Install the engine cover. 12. Install the grille. 13. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 14. Leak test the fittings of the component using the J 39400-A. 15. Install the air cleaner. 16. Connect the IAT sensor. 17. Connect the MAF sensor. Accumulator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7441 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator outlet side tube (3) from the rear tube. 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator outlet side tube from the compressor hose assembly. 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7442 7. Remove the bolts (1) that retain the clips on the outlet side tube (3) to the body. 8. Remove the auxiliary evaporator side tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator outlet side tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts (1) that retain the clips on the outlet side tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7443 4. Install the auxiliary evaporator outlet side tube to the compressor hose assembly. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 5. Install the new O-ring seal. 6. Install the auxiliary evaporator outlet underside body tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Compressor/Condenser Hose Replacement - Auxiliary TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7444 1. Disconnect the IAT sensor. 2. Disconnect the MAF sensor. 3. Remove the air cleaner. 4. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 5. Remove the grille. 6. Remove the engine cover. 7. Raise vehicle. Refer to Lifting and Jacking the Vehicle. 8. Disconnect the auxiliary evaporator lines nut from the compressor hose assembly. 9. Lower vehicle. 10. Remove the nut that attaches the compressor hose assembly bracket to the engine. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7445 11. Remove the hose clamp bracket nut (3) from the engine stud. 12. Remove the compressor hose assembly bolt from the compressor. 13. Remove the sealing washers from the compressor. 14. Remove the compressor hose assembly nut (6) from the condenser. 15. Remove the compressor hose assembly nut (1) from the accumulator. 16. Remove the compressor hose assembly from the vehicle. 17. Cap or plug all open connections. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7446 INSTALLATION PROCEDURE 1. Uncap or unplug all open connections. 2. Install the compressor hose assembly to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the compressor hose assembly nut (1) to the accumulator. Tighten Tighten the compressor hose assembly nut (1) to the accumulator to 48 N.m (35 lb ft). 4. Install the compressor hose assembly nut (6) to the condenser. Tighten Tighten the compressor hose assembly nut to the condenser to 28 N.m (21 lb ft). 5. Install new seal washers to the compressor. 6. Install the compressor hose assembly bolt to the compressor. Tighten Tighten the bolt to 34 N.m (25 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7447 7. Install the hose clamp bracket nut (3) to the engine stud. Tighten Tighten the nut to 5 N.m (44 lb in). 8. Install the nut that attaches the compressor hose assembly bracket to the engine. Tighten Tighten the nut to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7448 9. Raise the vehicle. 10. Connect the auxiliary evaporator hose nut to the compressor hose assembly. Tighten Tighten the nut to 28 N.m (21 lb ft). 11. Lower the vehicle. 12. Install the engine cover. 13. Install the grille. 14. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 15. Leak test the fittings of the component using the J 39400-A. 16. Install the air cleaner. 17. Connect the IAT sensor. 18. Connect the MAF sensor. Evaporator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 3. Remove the evaporator tube (2) from the evaporator. 4. Remove the O-ring seal. 5. Remove the grille. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7449 6. Remove the evaporator tube (2) from the condenser (4). 7. Remove the O-ring seal. 8. Remove the evaporator tube from the auxiliary A/C evaporator underbody front tube assembly (if equipped). INSTALLATION PROCEDURE 1. Install the NEW O-ring seal. 2. Install the evaporator tube (2) to the condenser (4). NOTE: Refer to Fastener Notice in Caution and Notices. 3. Tighten the evaporator tube nut (3) to the condenser (4). Tighten Tighten the nut to 28 N.m (20 lb ft). 4. Install the grille. 5. Install the new O-ring seal. 6. Install the evaporator tube to the evaporator. Tighten Tighten the nut to 28 N.m (20 lb ft). 7. Install the evaporator tube to the auxiliary A/C evaporator underbody front tube assembly (if equipped). Tighten Tighten the evaporator tube nut to the auxiliary A/C evaporator to 28 N.m (20 lb ft). 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. 10. Install the air cleaner. Evaporator Tube Replacement - Auxiliary Front TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7450 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator front inlet tube from the evaporator inlet tube (2) at the accumulator. 4. Remove the O-ring seal. 5. Remove the bolts (3) that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. 6. Remove the auxiliary evaporator front inlet tube (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator front inlet tube (2) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts that retain the clips on the auxiliary evaporator front inlet tube (2) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. 4. Install the auxiliary evaporator front inlet tube (2) to the auxiliary evaporator side inlet tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Lower the vehicle. 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7451 Evaporator Tube Replacement - Auxiliary Rear TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator rear outlet tube from the auxiliary evaporator outlet side tubes. 4. Remove the auxiliary evaporator rear inlet tube from the auxiliary evaporator inlet side tubes. 5. Remove the bolts that retain the clips on the tubes to the body. 6. Remove the nut that retains the tube to the auxiliary evaporator module. 7. Remove the tube from the auxiliary evaporator module. 8. Remove the seal washers INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7452 1. Install the seal washers. 2. Install the tube to the auxiliary evaporator module. NOTE: Refer to Fastener Notice in Caution and Notices. 3. Install the nut that retains the tube to the auxiliary evaporator module. Tighten Tighten the nut to 25 N.m (18 lb ft). 4. Install the bolts that retain the clips on the tubes to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 5. Install the auxiliary evaporator rear tube inlet tube to the auxiliary evaporator inlet side tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 6. Install the auxiliary evaporator rear tube outlet tube to the auxiliary evaporator outlet side tube. Tighten Tighten the nut to 47.5 N.m (35 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7453 9. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. Evaporator Tube Replacement - Auxiliary Side TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator rear tube (3). 4. Remove the O-ring seal. 5. Remove the auxiliary evaporator side inlet tube from the auxiliary evaporator front tube (2). 6. Remove the O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7454 7. Remove the bolts (1) that retain the clips on the auxiliary side inlet tube (3) to the body. 8. Remove the auxiliary evaporator side inlet tube (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary evaporator side inlet tube (3) to the vehicle. NOTE: Refer to Fastener Notice in Caution and Notices. 2. Install the bolts that retain the clips on the auxiliary evaporator side inlet tube (3) to the body. Tighten Tighten the bolts to 4 N.m (35 lb in). 3. Install the new O-ring seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement > Page 7455 4. Install the auxiliary evaporator side inlet tube to the auxiliary evaporator front inlet tube (2). Tighten Tighten the nut to 27 N.m (20 lb ft). 5. Install the new O-ring seal. Coat the O-ring seal with 525 viscosity refrigerant oil. 6. Install the auxiliary evaporator side inlet tube (3) to the auxiliary evaporator rear tube. Tighten Tighten the nut to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair HEATER MODULE REPLACEMENT - AUXILIARY REMOVAL PROCEDURE 1. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the body side front lower trim panel. 3. Remove the auxiliary heater module cover retaining screws. 4. Remove the auxiliary heater module cover. 5. Remove the auxiliary heater pipe clamps. 6. Disconnect the auxiliary heater pipes from the auxiliary heater module. 7. Remove the bolts retaining the auxiliary heater module to the floor. IMPORTANT: Before removing the auxiliary heater module from the vehicle, be sure to place a protective cover on the floor in order to prevent coolant from leaking onto the carpet. 8. Remove the auxiliary heater module from the vehicle. INSTALLATION PROCEDURE 1. Install the auxiliary heater module. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7459 2. Install the bolts that retain the auxiliary heater module to the floor. Tighten Tighten the bolts to 5 N.m (44 lb in). 3. Connect the auxiliary heater pipes to the auxiliary heater module. 4. Install the auxiliary heater pipe clamps. 5. Install the auxiliary heater module cover. 6. Install the auxiliary heater module cover retaining screws. Tighten Tighten the screws to 5 N.m (44 lb in). 7. Install the body side front lower trim panel. 8. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7464 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7465 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ....................................................... 2.0 lb. (0.91 kg.) Air Conditioning Refrigerant with Rear A/C .............................................................................................................................................. 3.0 lb. (1.36 kg.) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7468 Refrigerant: Fluid Type Specifications Type R-134a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7469 Refrigerant: Service Precautions CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7470 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED ^ J 43600 ACR 2000 Air Conditioning Service Center ^ J 45037 A/C Oil Injector CAUTION: ^ Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. ^ For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: ^ R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. ^ To avoid system damage use only R-134a dedicated tools when servicing the A/C system. ^ Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. ^ R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port.. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7475 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1) tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7476 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7477 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7478 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7479 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7480 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The ruts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7481 7. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7482 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7483 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7484 7. Remove the A/C refrigerant filter (6) from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7485 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7486 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port.. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7487 IMPORTANT: DO NOT install the O-rings (2) in this step. 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. 14. While holding the evaporator tube in the A/C refrigerant filter (1) tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7488 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Installation (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector IMPORTANT: The A/C refrigerant filter, ACDelco P/N 15-1697 must be installed to the A/C evaporator tube between the condenser and evaporator. The installation of this A/C refrigerant filter eliminates the need for flushing. 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. 6. Measure 40 mm (1.5 in) from the bend on the evaporator tube (1) near the high side access port. 7. Measure 50.8 mm (2 in) from the mark on the evaporator tube (1) from the previous step. IMPORTANT: Do not allow metal burrs to enter the evaporator tube (1) during cutting or when removing the burrs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7489 8. Using a tubing cutter, cut the marked section of the evaporator tube (1). 9. Remove the burrs from the evaporator tube (1). 10. Remove the nuts (4), the ferrules (3), and the O-rings (2) from the A/C refrigerant filter (1). IMPORTANT: DO NOT install the O-rings (2) in this step. 11. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves. 12. Install the ferrules (3) with the small end toward the nut (4). 13. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7490 14. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 15. Remove the nuts (4) from the A/C refrigerant filter (1). 16. Coat the O-rings (2) with 525 viscosity refrigerant oil. 17. Install the O-rings (2) to the evaporator tube. 18. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 19. Install the evaporator tube (1) to the vehicle. 20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 21. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 22. Install the upper radiator shroud. 23. Install the grille. 24. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Replacement (C60) TOOLS REQUIRED J 39400-A Halogen Leak Detector Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7491 REMOVAL PROCEDURE 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The ruts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7492 7. Remove the A/C refrigerant filter from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7493 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Air Conditioning (A/C) Refrigerant Filter Replacement (C69) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7494 1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner. 3. Remove the upper radiator shroud. 4. Remove the grille. 5. Remove the evaporator tube (1) from the vehicle. IMPORTANT: The nuts (4) and ferrules (3) will remain on the evaporator tube. Do not try to remove. 6. Remove the nuts (4) from the A/C refrigerant filter (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7495 7. Remove the A/C refrigerant filter (6) from the evaporator tube (1). INSTALLATION PROCEDURE 1. Install the new O-rings (2) to the evaporator tube. 2. Install the A/C refrigerant filter (6) to the evaporator tube (1) with the flow arrow pointing towards the evaporator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7496 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (4) to the A/C refrigerant filter (1). Tighten Tighten the nuts to 15 N.m (11 lb ft). 4. Install the evaporator tube. 5. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 7. Install the grille. 8. Install the upper radiator shroud. 9. Install the air cleaner. For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID. See: Application and ID/RPO Codes Suction Screen Installation TOOL REQUIRED J 44551 Suction Screen Installation/ Removal Kit IMPORTANT: Suction screens are intended to be installed in the suction hose after a major compressor failure. The suction screens are available in 3 different sizes. 1. Insert the J 44551-5 sizing tool into the suction hose to select the correct size suction screen. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation (C60) > Page 7497 2. Insert the suction screen into the compressor end of the suction hose. 3. Install the correct mandrel to the J 44551-5. 4. Install the J 44551-5 screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting. 6. Remove the J 44551-5 suction screen tool from the suction hose. IMPORTANT: After major compressor failure a A/C refrigerant filter should also be installed. 7. Install an A/C refrigerant filter. 8. Install the J 44551-1 Suction Screen Notification label. Suction Screen Replacement TOOLS REQUIRED ^ J 42220 Universal Leak Detection Lamp ^ J 44551 Suction Screen Kit REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the Engine cover. 3. Remove the A/C compressor hose assembly bolt. 4. Separate the A/C compressor hose assembly from the A/C compressor. IMPORTANT: The suction screens are available in 3 different sizes. 5. Select the proper size removal tool from the J 44551. 6. Remove the suction screen using the J 44551-31 suction screen removal tool. ^ Thread the forcing screw into the suction screen. ^ Tighten the nut on the forcing screw to remove the suction screen. INSTALLATION PROCEDURE 1. Insert the J 44551-6 sizing tool into the suction hose to select the correct size suction screen. 2. Insert the suction screen into the suction hose. 3. Install the J 44551-3 mandrel to the J 44551-5. 4. Install the J 44551-5 suction screen installation tool over the end of the suction hose and the suction screen. IMPORTANT: Correct placement of the J 44551-5 is critical. 5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose. 6. Remove the J 44551-5 suction screen tool from the suction hose. 7. Replace the seal washers. 8. Install the A/C compressor hose assembly to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 9. Install the A/C compressor hose assembly bolt. Tighten Tighten the bolt to (25 lb ft). 10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the component using the J 42220. 12. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant System Capacities - Heating, Ventilation And Air Conditioning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7504 Refrigerant Oil: Fluid Type Specifications PAG (Polyalkaline Glycol) synthetic refrigerant oil (GM part number 12345923) or equivalent. For Canada use GM P/N 10953486. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7505 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7510 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED ^ J 5403 Snap Ring Pliers ^ J 9553-01 O-Ring Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. Refer to Refrigerant Recovery and Recharging. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7511 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7515 A/C Low Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7516 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (2) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch (1) to the accumulator (3). Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair BLOWER MOTOR RELAY REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The blower motor relay that is used on the M/L van is an integral part of the blower motor resistor and can not be serviced separately from the resistor. 1. Remove the air cleaner. 2. Remove the windshield washers and the coolant reservoir. 3. Disconnect the electrical connectors. 4. Remove the screws from the blower motor resistor assembly. 5. Remove the blower motor resistor assembly (4). INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly (4). NOTE: Refer to Fastener Notice 2. Install the screws to the blower motor resistor assembly. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the windshield washers and the coolant reservoir. 4. Connect the electrical connectors. 5. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7524 Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the cover from the underhood convenience center. 2. Remove the compressor relay (2). INSTALLATION PROCEDURE 1. Install the compressor relay (2). 2. Install the cover to the underhood convenience center. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Air Temperature Sensor Resistance Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7529 Ambient Air Temperature Sensor (DIC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7530 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the radiator grille from the vehicle. 2. Remove the outside air temperature sensor from the center support bracket by sliding the sensor upward. 3. Disconnect the temperature sensor electrical connector. INSTALLATION PROCEDURE 1. Connect the temperature sensor electrical connector. 2. Install the temperature sensor by sliding the sensor downward. 3. Install the radiator grille to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7534 Blower Motor Switch: Diagrams Blower Motor Switch - A/C Auxiliary - HVAC Systems - Manual Blower Motor Switch - Heater Auxiliary Part 1 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7535 Blower Motor Switch - Heater Auxiliary Part 2 - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Auxiliary Air Conditioning REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary A/C blower motor switch (2) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7538 1. Install the auxiliary A/C blower motor switch (2) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7539 Blower Motor Switch: Service and Repair Blower Motor Switch Replacement - Heater Auxiliary REMOVAL PROCEDURE 1. Set the parking brake, turn the ignition key to the ON position and move the gear selector to 1st gear position. 2. Lower the tilt steering column to the lowest position. 3. Pull the instrument panel cluster trim plate rearward by grasping it around the edges until the retainers release from the instrument panel. 4. Remove the auxiliary heat blower motor switch (1) from the instrument panel cluster trim plate (3) by releasing the tabs located on the sides of each switch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Replacement - Auxiliary Air Conditioning > Page 7540 1. Install the auxiliary heat blower motor switch (1) to the instrument panel cluster trim plate (3) by engaging the tabs located on the sides of each switch. 2. Install the instrument panel cluster trim plate by aligning the retainers to the opening in the instrument panel and push in place until fully seated. 3. Move gear selector into PARK position, turn the ignition to the OFF position and release the park brake. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams A/C High Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7545 High Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT TOOLS REQUIRED ^ J 5403 Snap Ring Pliers ^ J 9553-01 O-Ring Remover ^ J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the engine cover. 2. Recover the refrigerant the system. Refer to Refrigerant Recovery and Recharging. 3. Clean the control A/C high pressure switch area before removing the snap ring. 4. Disconnect the electrical connector from the A/C high pressure switch (2) in the rear head of the compressor. 5. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. 6. Remove the A/C high pressure switch (2) from the compressor. 7. Remove the old O-ring seal from the A/C high pressure switch cavity using the J 9553-01. 8. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary. INSTALLATION PROCEDURE IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring is included in a new switch kit. 1. Lubricate the new O-ring using new 525 viscosity refrigerant oil. 2. Install the new O-ring into the groove in the switch cavity. 3. Lubricate the control switch housing using new 525 viscosity refrigerant oil. 4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity. 5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or J 5403. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 7546 6. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 7. Leak test the fitting(s) of the repaired or reinstalled components using the J 39400-A. 8. Install the engine cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7550 A/C Low Pressure Switch - HVAC Systems - Manual Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7551 Low Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) LOW PRESSURE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch (2) from the accumulator (3). INSTALLATION PROCEDURE 1. Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil. 2. Install the NEW O-ring seal to the switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C low pressure switch (1) to the accumulator (3). Tighten Tighten the switch to 6 N.m (53 lb in). 4. Connect the electrical connector to the A/C low pressure switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE HARNESS REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the vacuum supply lines (3) from the cowl panel under the hood. 2. Disconnect the vacuum supply lines (2) from the vacuum harness in the vehicle. 3. Remove the vacuum supply lines harness and grommet (1) from the cowl panel by grasping the grommet at the base and pulling rearward. 4. Remove the vacuum supply harness. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair > Page 7555 1. Install the vacuum supply harness. 2. Install the vacuum supply lines harness and grommet (1) to the corner of the cowl panel. 3. Insert the vacuum supply lines harness and grommet to the cowl panel hole, push inward until fully seated. 4. Connect the vacuum supply lines (2) to the vacuum harness. 5. Connect the vacuum supply lines (3) to the cowl panel under the hood. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM TANK REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner. 2. Remove the upper fan shroud. 3. Remove the vacuum hose(s). 4. Remove the screws from the vacuum tank. 5. Remove the vacuum tank. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair > Page 7559 1. Install the vacuum tank. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the vacuum tank. Tighten Tighten the screws to 3 N.m (26 lb in). 3. Install the vacuum hose(s). 4. Install the upper fan shroud. 5. Install the air cleaner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System Accident With Frontal Air Bag Deployment CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. After a collision involving frontal air bag deployment, replace the following components. ^ Inflatable restraint electronic frontal sensor (EFS) ^ Inflatable restraint front end discriminating sensor ^ Inflatable restraint IP module ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint steering wheel module Perform additional inspections on the following components. ^ Steering wheel module coil and coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. ^ Mounting points and mounting hardware for the EFS, front end discriminating sensor, IP module, steering wheel module, and SDM - Inspect for damage and repair or replace each component as needed. Accident With Side Air Bag Deployment CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than Intended. After a collision involving side air bag deployment, replace the following components. ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact module, on side of impact ^ Inflatable restraint side impact sensor (SIS), on side of impact Perform additional inspections on the mounting points and mounting hardware for the side impact module, SIS, and SDM - Inspect for damage and repair or replace each component as needed. Accident With/Without Air Bag Deployment After a collision, the following components need to be inspected as indicated. If any damage is detected, replace the component. If damage to the mounting points or mounting hardware is detected, repair or replace the mounting points and mounting hardware as needed. ^ Steering column - Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection - Off Vehicle in Steering Wheel and Column. ^ I/P Knee Bolsters and Mounting Points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. ^ I/P brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage. ^ Seat Belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. ^ Seats and Seat Mounting Points - Inspect for bending, twisting, buckling, or any other type of damage. After inspecting the components listed above, proceed to the following Component Replacement and Inspections if air bag deployment has occurred. Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of collision damage. The area of collision damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. ^ Replace the sensor even if the air bags have not deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7565 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: ^ Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. ^ Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. ^ Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. ^ Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7566 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection - Off Vehicle Notice: Vehicles involved in accidents that result in any of the following kinds of damage or situations, may also have a damaged or misaligned steering column: Frame damage - Major body damage - Sheet metal damage - If the steering column has been impacted - If the supplemental inflatable restraints system was deployed - Check the capsules on the steering column bracket assembly: all must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. Important: If measured dimensions are not within specifications, a new jacket must be installed. Check for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. - Remove the inflatable restraint steering wheel module coil. - Visually inspect steering shaft for sheared injected plastic (1). If steering shaft shows sheared plastic, a new steering shaft must be installed. - Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked in the following manner. Using a dial indicator at the lower end of the steering shaft, have the steering wheel rotated. Runout must not exceed 1.60 mm. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 7572 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESSES The inflatable restraint wiring harnesses connect the Sensing And Diagnostic Module (SDM), inflator modules, discriminating sensor, and the class 2 serial data circuit together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing SIR system wiring harnesses, follow the proper testing and wiring repair procedures outlined. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7580 Inflatable Restraint Sensing And Diagnostic Module (SDM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7581 Air Bag Control Module: Service Precautions CAUTION: ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than Intended. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7582 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7583 Air Bag Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7584 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7585 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7586 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7590 Clockspring Assembly / Spiral Cable: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7591 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE CAUTION: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the steering column trim covers. 3. Remove the wire harness assembly (4) from the wire harness strap (5). 4. Remove the 3 wire harness straps (3) from the wire harness assembly. 5. Remove the wire harness strap (2) from the upper tilt head assembly (1). 6. Remove the SIR steering wheel module coil retaining clip (1). 7. Remove the SIR steering wheel module coil (2). 8. Remove the wave washer (3) from the steering column upper shaft. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7592 1. Align the block tooth on the upper shaft to the 12 o'clock position. NOTE: Ensure all fasteners are securely seated before applying needed torque. Failure to do so may result in component damage or malfunctioning of steering column. 2. Install the wave washer (1) to the steering column upper shaft. IMPORTANT: ^ Verify that the SIR steering wheel module coil is centered. ^ The SIR steering wheel module coil becomes uncentered under the following conditions: The steering column is separated from the steering gear and allowed to rotate. - The centering spring is pushed down, letting the hub rotate while the coil is removed from the steering column. ^ If the SIR steering wheel module coil becomes uncentered, refer to Inflatable Restraint Coil Centering - Off Vehicle (Column Shift And Floor Shift) in Steering Wheel and Column. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7593 3. Align the SIR steering wheel module coil (2) with the horn tower on the turn signal cancel cam (1) 4. Install the pre-centered SIR steering wheel module coil (2) to the steering column upper shaft. 5. Remove the centering tab (1) and discard. NOTE: Gently pull on the lower coil assembly wire in order to remove any wire kinks inside of the column assembly. Verify that there are NO kinks or bends in the SIR coil assembly wire. If a kink or bend is present, interference may occur with the shaft lock mechanism. Turning the steering wheel may cut or damage the wire. 6. Install the SIR steering wheel module coil retaining ring. Verify that the ring (1) is firmly seated in the groove on the upper shaft (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 7594 7. Install the wire harness assembly (4) into the wire strap (5). 8. Install the wire harness strap (2) into the wire strap (1). 9. Install wire harness straps (3) to the wire harness assembly. 10. Install the steering column trim covers. 11. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7598 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7599 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7600 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7601 Impact Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Disconnect the mass air flow (MAF) and the intake air temperature (IAT) sensors harness connectors. 3. Loosen the clamp. 4. Remove the air tube from the throttle body air intake cover. 5. Remove the bolts. 6. Remove the upper radiator shroud. 7. Remove the fan and clutch assembly. 8. Remove the lower radiator shroud. 9. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the cradle (1). 10. Remove the bolts (2). 11. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the top of the cradle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7604 Tighten Tighten fastener to 6.5 N.m (58 lb in). IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. 3. Perform the following steps in order to complete the first fastener repair; 3.1. Remove and discard the improperly installed rivet. 3.2. Reattach sensor with new rivet (GM P/N 15715058) or equivalent. 4. Perform the following steps, if needed, in order to complete a second fastener repair: 4.1. Remove the improperly installed rivet. 4.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 4.3. Insert and properly seat rivnut (GM P/N 15699834) or equivalent. 4.4. Install sensor with screw GM P/N 11515664, or equivalent. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 5. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 6. Install the lower radiator shroud. 7. Install the fan and clutch assembly. 8. Install the upper radiator shroud. 9. Install the air box with MAF sensor to the upper radiator shroud. 10. Connect the air tube to the throttle body air intake cover with the clamp. 11. Connect the MAF and IAT sensors harness connectors. 12. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7605 Impact Sensor: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7606 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7607 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7608 Impact Sensor: Service and Repair SIR Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of collision damage. The area of collision damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. ^ Replace the sensor even if the air bags have not deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Testing and Inspection Side Air Bag: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Testing and Inspection > Page 7616 Side Air Bag: Service and Repair SIDE AIR BAG DEPLOYMENT - COMPONENT REPLACEMENT AND INSPECTIONS CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than Intended. After a collision involving side air bag deployment, replace the following components. ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Inflatable restraint side impact module, on side of impact ^ Inflatable restraint side impact sensor (SIS), on side of impact Perform additional inspections on the mounting points and mounting hardware for the side impact module, SIS, and SDM - Inspect for damage and repair or replace each component as needed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with ignition 1 voltage and the IPC flashes the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the class 2 serial data circuit and request the IPC to turn the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a Diagnostic Trouble Code (DTC) and request the IPC to turn the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision the front seat occupants legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damage after a collision. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Right REMOVAL PROCEDURE 1. Remove the passenger's knee bolster. IMPORTANT: Do not remove the instrument panel to replace right or right center knee bolster brackets. 2. Roll the instrument panel down. Refer to IP Assembly Replacement. 3. Remove the knee bolster bracket right side screws. 4. Remove the knee bolster bracket right side. 5. Remove the knee bolster bracket right center screws. 6. Remove the knee bolster bracket right center. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7629 1. Install the knee bolster bracket right center. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster bracket right center screws. Tighten Tighten the knee bolster bracket right center screws to 8 N.m (71 lb in). 3. Install the knee bolster bracket right side. Install the knee bolster bracket right side screws. Tighten Tighten the knee bolster bracket right side screws to 8 N.m (71 lb in). 4. Roll the instrument panel up. Refer to IP Assembly Replacement. 5. Install the passenger's knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7630 Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Left REMOVAL PROCEDURE 1. Remove the driver's knee bolster. 2. Remove the bolts that retain the brackets to the instrument panel trim pad. 3. Roll the instrument panel back, but do not remove the instrument panel. Refer to IP Assembly Replacement. 4. Remove the bolts that retain the knee bolster brackets to the instrument panel carrier. 5. Remove the knee bolster brackets from the vehicle. INSTALLATION PROCEDURE 1. Install the knee bolster brackets to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the brackets to the instrument panel carrier. Tighten Tighten the bolts to the brackets to the instrument panel carrier to 10 N.m (89 lb in). 3. Install the instrument panel to the vehicle. 4. Install the bolts that retain the brackets to the instrument panel trim pad. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7631 Tighten the bolts that retain the bracket to the instrument panel to 10 N.m (89 lb in). 5. Install the driver's knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7632 Knee Diverter: Service and Repair Knee Bolster Replacement - Left REMOVAL PROCEDURE 1. Remove the screws that retain the bolster to the instrument panel. 2. Pull back on the bolster in order to release the two retainers and remove the bolster. 3. Remove the parking brake release lever from the knee bolster. INSTALLATION PROCEDURE 1. Install the parking brake release lever to the knee bolster. 2. Install the knee bolster: 2.1. Align the retainers. 2.2. Press the panel into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the knee bolster to the instrument panel. Tighten Tighten the knee bolster screws to 8 N.m (71 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7633 Knee Diverter: Service and Repair Knee Bolster Deflector Replacement - Left REMOVAL PROCEDURE 1. Remove the instrument panel extension. 2. Remove the driver's knee bolster. 3. Remove the nuts that retain the knee bolster deflector to the instrument panel carrier. 4. Remove the bolts that retain the knee bolster deflector to the instrument panel carrier. 5. Remove the knee bolster deflector from the vehicle. INSTALLATION PROCEDURE 1. Install the knee bolster deflector to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts that retain the knee bolster deflector to the instrument panel carrier. Tighten Tighten the bolts that retain the knee bolster deflector to the instrument panel carrier 10 N.m (89 lb in). 3. Install the bolts that retain the knee bolster deflector to the instrument panel carrier. Tighten Tighten the nuts that retain the knee bolster deflector to the instrument panel carrier to 10 N.m (89 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7634 4. Install the driver's knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7635 Knee Diverter: Service and Repair Knee Bolster Replacement - Right REMOVAL PROCEDURE 1. Remove the instrument panel extension. 2. Remove the screws that retain the knee bolster to the instrument panel. 3. Pull back on the knee bolster in order to release the retainers from the instrument panel. 4. Remove the knee bolster. INSTALLATION PROCEDURE 1. Install the knee bolster. 2. Install the knee bolster to the instrument panel: 2.1. Align the retainers. 2.2. Press the panel into place. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the bolster to the instrument panel. Tighten Tighten the knee bolster screws to 8 N.m (71 lb in). 4. Install the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7640 Inflatable Restraint Sensing And Diagnostic Module (SDM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7641 Air Bag Control Module: Service Precautions CAUTION: ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended. ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s) for conditions less severe than Intended. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7642 Air Bag Control Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The Sensing And Diagnostic Module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with several external sensors, if equipped, mounted at various locations on the vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7643 Air Bag Control Module: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7644 Air Bag Control Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7645 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7646 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 7652 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Top Teather Attachment Kits Bulletin No.: 99-09-40-004a Date: April 12, 2005 INFORMATION Subject: Top Tether Hardware Package for Child Restraint Seats Models: 1989-2002 Passenger Cars, Light Duty Trucks and Multi-Purpose Passenger Vehicles (Except EV1 and Prizm) Supercede: This bulletin is being revised to add the 2000-2002 model years. Please discard Corporate Bulletin Number 99-09-40-009 (Section 09 - Restraints). Important: GM of Canada and IPC Dealers are not authorized to utilize this service bulletin. Beginning in August, 1997 General Motors began providing Child Restraint Seat Top Tether Hardware Packages to customers in the United States who requested them. The Top Tether Hardware Package contains the necessary hardware for anchoring a forward facing child restraint seat top tether. One Child Restraint Seat Top Tether Hardware Package will be provided per vehicle to the retail customer at no charge for installation. Charges for installation of additional Top Tether Hardware Packages per vehicle are the responsibility of the customer. Most forward facing child restraint seats (CRS) sold in the United States prior to calendar year 1999 were not sold with top tether straps, but have provisions for them. Top tethers, which are required in Canada, can help to better secure the seat in the vehicle. When a forward facing CRS including a top tether is used, specially designed components must be used to secure the child seat top tether. These components are included in the Hardware Package from GMSPO. Top tethers are not normally required or used with rearward facing infant restraint seats. Rearward facing infant restraint seats should never be secured in the front seat of an air bag equipped vehicle unless the vehicle is equipped with an air bag de-activation (shut-off) switch and the switch has been used to turn the air bag off. Should a retail customer request installation of a Tether Hardware Package at the time of sale or delivery, it is to be installed at no charge to the owner. The labor to install a Tether Hardware Package prior to delivery of a new vehicle to the customer is considered to be part of the delivery "get ready process", and as such, is not claimable. Claiming for the cost and applicable handling allowance of the proper Tether Hardware Package used in the installation is allowed. If the customer requests installation of a Tether Hardware Package some time after delivery, the package is to be provided free of charge. Hardware Packages include installation instructions which are easily followed and can be installed by most customers. However, should the customer request the dealership's assistance to install the Tether Hardware Package, it is to be installed at no charge to the customer and the labor may be claimed. All claims submitted for installation labor of an approved Tether Hardware Package must be supported by a signed customer work order. Additional Hardware Packages and installation charges are the responsibility of the customer. In addition, passenger vehicle deliveries, including vans and sport utilities for daily rental usage, may have one tether hardware package supplied. Additional packages are the owner's responsibility. Dealers may claim appropriate parts under these circumstances. Sufficient quantities of parts should be ordered in advance of the arrival of vehicles to avoid delays. Important: When installing a Child Restraint Seat Top Tether Hardware Package, follow the installation instructions included in the package. Additional information about specific mounting locations and installations may be available in the Seat Belt Section (Sections 9, 10-10, 10-11 or 10A) I of the appropriate Service Manual, or the Restraints section of SI. Any questions regarding this policy should be directed to your Area Manager, Parts or Service. Parts Information For Top Tether Hardware Package part numbers and usage, see Group 14.870 (passenger cars & U-van), or Group 16.710 (Light Duty Truck) of the appropriate GMSPO Parts Catalog. In addition, they can also be found in Accessories Group 21.042. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Top Teather Attachment Kits > Page 7658 Warranty Information The dealership will be reimbursed for the parts and labor, if applicable, through the submission of a regular warranty claim. All claims submitted must be supported by a signed customer work order. Purchase and installation of additional Hardware Packages is the responsibility of the customer. For Top Tether Hardware Packages installed in the United States, submit as a normal warranty claim using the labor operations and time allowances shown. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 7659 Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. Inspect the seat belt tether spacer bar hook (1) for damage. If damaged, replace the bucket seat riser spacer bar. Refer to Seat Riser Trim Cover Replacement - Power in Seats. 2. The front bucket seat passenger side tether belt (2) runs down the center of seatback and hooks to the seat belt tether spacer bar (4) located in the center of the seat riser. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 7660 3. For the bench seats YC6, the tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Refer to Sear Belt Buckle and Latch Replacement - No. 2 Rear. 4. For the bench seats YC7, the seat belt tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Refer to Seat Belt Buckle and Latch Replacement - No. 2 Rear. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 7661 1. For the bench seats YC7, the seat belt tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Refer to Seat Belt Buckle and Latch Replacement - No. 2 Rear. 2. For the bench seats YC6, the tether belt must run under the headrest and hook into the seat belt tether anchor. Located behind the seatback and integrated into the center seat belt. If the seat belt tether anchor or seat belt are damaged the rear center seat belts must be replaced. Refer to Sear Belt Buckle and Latch Replacement - No. 2 Rear. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 7662 3. The front bucket seat passenger side tether belt (2) runs down the center of seatback and hooks to the seat belt tether spacer bar (4) located in the center of the seat riser support bar. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions Seat Belt: Service Precautions IMPORTANT: If the vehicle has been in a collision, refer to Repairs and Inspections Required After a Collision for additional information. ^ Do not bleach or dye the seat belt webbing. Use only the following items in order to clean the seat belt webbing: A mild soap and water solution - A soft brush or cloth ^ Keep sharp edges and damaging objects away from the seat belts. Do not bend or damage any part of the seat belt buckle or latch plate. Replace any seat belts that are cut or damaged in any manner. ^ Use only the correct seat belt anchor bolts. Tighten the correct seat belt anchor bolt/ screw to the correct torque value. Refer to Fastener Tightening Specifications. Begin tightening the seat belt anchor bolts by hand in order to ensure that the bolt is threaded straight. ^ Some seat belts and retractors require service as a set with service replacement components only. Do not repair individual components that require service as a set. ^ Verify that the replacement part number is correct for the vehicle at that seating position. Do not substitute a seat belt from a different seating position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service Precautions > Page 7666 Seat Belt: Description and Operation FRONT SEAT BELT SYSTEM OPERATION CAUTION: To help avoid personal injury from unrepaired crash damage to a restraint system, perform the seat belt check for each seat belt system. Replace the seat belt system if there is any doubt about the condition of system components. 1. The front seat belt system includes a driver and/or passenger seat belt retractor and buckle. 2. The LF seat belt system, includes a seat belt switch in the LF seat buckle which controls a fasten safety belts indicator and a tone alarm. When the LF seat belt is buckled, the LF door is closed, and the ignition switch is in the ON position, the following events will not occur: ^ The tone alarm will not operate. ^ The fasten safety belts indicator will not operate. 3. When the LF seat belt is not buckled, the LF door closed, and the ignition switch is in the RUN position, the following events will occur: ^ The tone alarm will operate for 4 to 8 seconds and then turn OFF. ^ The fasten safety belts indicator will operate for 20 seconds, until the LF seat belt is buckled. ^ Then the fasten safety belts indicator will flash for an additional 55 seconds before turning OFF. To diagnose a failure of the fasten safety belts indicator refer to Symptoms - Seat Belts or the tone alarm, refer to Audible Warnings in Instrument Panel, Gauges and Console. SEAT BELT SYSTEM CIRCUIT DESCRIPTION The fasten safety belts indicator will illuminate when the following conditions occur simultaneously: ^ The ignition switch is in one of the following positions: RUN - BULB TEST - START ^ The LF safety belt is not fastened. The audio fasten safety belt warning alarm, located within the Body Control Module (BCM), also incorporates an indicator within the Instrument Panel Cluster (IPC). The fasten safety belt indicator works in conjunction with the fasten safety belt warning alarm. When the BCM receives a signal that the LF safety belt is unfastened, the BCM sends a signal to the IPC to command ON the fasten safety belt indicator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7675 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7681 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle: Service and Repair Rear REMOVAL PROCEDURE 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Install the seat belt buckle to the floor stud. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts located at the base of the seat riser. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7684 Seat Belt Buckle: Service and Repair Front REMOVAL PROCEDURE 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Disconnect the seat belt buckle warning lamp electrical connector. 4. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Connect the seat belt buckle warning electrical connector. 3. Install the seat belt buckle to the floor stud. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts located at the base of the seat riser. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7685 Seat Belt Buckle: Service and Repair Center Rear REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt buckle retaining bolt from the seat frame. 3. Remove the seat belt buckle through the seat back. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7686 1. Install the seat belt buckle through the seat back. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle retaining bolt to the seat frame. Tighten Tighten the seat belt buckle bolt to the seat frame to 53 N.m (39 lb ft). 3. Install the rear bench seat to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7687 Seat Belt Buckle: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle latch to the side of the riser. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle latch bolt. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7688 Seat Belt Buckle: Service and Repair Rear REMOVAL PROCEDURE 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Install the seat belt buckle to the floor stud. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts located at the base of the seat riser. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Front REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7689 1. Remove the nuts located on the inside of the seat riser. 2. Remove the seat belt buckle from the floor stud by lifting upward on the seat. The seat does not have to be removed from the vehicle. 3. Disconnect the seat belt buckle warning lamp electrical connector. 4. Remove the seat belt buckle. INSTALLATION PROCEDURE 1. Install the seat belt buckle. 2. Connect the seat belt buckle warning electrical connector. 3. Install the seat belt buckle to the floor stud. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the nuts located at the base of the seat riser. Tighten Tighten the bucket seat to the floor to 35 N.m (26 lb ft). Center Rear REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7690 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt buckle retaining bolt from the seat frame. 3. Remove the seat belt buckle through the seat back. INSTALLATION PROCEDURE 1. Install the seat belt buckle through the seat back. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7691 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle retaining bolt to the seat frame. Tighten Tighten the seat belt buckle bolt to the seat frame to 53 N.m (39 lb ft). 3. Install the rear bench seat to the vehicle. Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7692 1. Install the seat belt buckle latch to the side of the riser. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle latch bolt. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Seat Belt Buckle and Latch Replacement - Rear (RPO ZP5) REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt latch by removing the hog rings and lifting up on the cover to expose the nut. The complete seat cover does not have to be removed. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7693 1. Install the seat belt latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt latch nut. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the seat cover and rehog ring it back in place. 4. Install the rear bench seat to the vehicle. For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Seat Belt Buckle and Latch Replacement - Rear (RPO ZP8) REMOVAL PROCEDURE 1. Remove the rear bench seat side cover screw to expose the seat belt latch bolt. 2. Remove the rear bench seat side cover screw. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7694 1. Install the seat belt latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt latch nut. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the rear bench seat side cover and screw. For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Seat Belt Buckle and Latch Replacement - No.2 Rear REMOVAL PROCEDURE 1. Remove the rear seat form the vehicle. 2. Remove the seat belt buckle and latch retaining bolt from the seat frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7695 3. Remove the seat belt buckle and latch through the seat back. INSTALLATION PROCEDURE 1. Install the seat belt buckle and latch through the seat back. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear > Page 7696 2. Install the seat belt buckle and latch retaining bolt to the seat frame. Tighten Tighten the seat belt buckle and latch retaining bolt to 53 N.m (39 lb ft). 3. Install the rear bench seat in the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7700 Seat Belt Buckle Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front Seat Belt Height Adjuster: Service and Repair Shoulder Belt Guide Adjuster Replacement - Front REMOVAL PROCEDURE 1. Remove the cover for the front seat shoulder belt to expose the bolt. 2. Remove the front seat shoulder belt retaining bolt from the guide adjuster bracket. 3. Remove the left front side door lock pillar garnish molding. 4. Remove the right front side door lock pillar garnish molding. 5. Remove the 2 guide adjuster bracket retaining bolts from the pillar. 6. Remove the guide adjuster bracket from the pillar. INSTALLATION PROCEDURE 1. Install the guide adjuster bracket to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 guide adjuster bracket retaining bolts to the pillar. Tighten Tighten the guide adjuster bracket retaining bolts to the pillar to 20 N.m (15 lb ft). 3. Install the left front side door lock pillar garnish molding. 4. Install the right front side door lock pillar garnish molding. 5. Install the shoulder belt retaining bolt to the guide adjuster bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7709 Tighten Tighten the front seat shoulder belt retaining bolt to the guide adjuster bracket to 53 N.m (39 lb ft). 6. Install the cover for the front seat shoulder belt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7710 Seat Belt Height Adjuster: Service and Repair Shoulder Belt Guide Adjuster Replacement - Rear REMOVAL PROCEDURE 1. Open the cover on the rear seat shoulder belt to expose the bolt. 2. Remove the rear seat shoulder belt retaining bolt from the guide adjuster bracket. 3. Remove the left rear - C-pillar side garnish molding trim by grasping both the sides and pull rearward. 4. Remove the 2 guide adjuster bracket retaining bolts from the pillar. 5. Remove the guide adjuster bracket from the pillar. INSTALLATION PROCEDURE 1. Install the guide adjuster bracket to the pillar. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 2 guide adjuster bracket retaining bolts to the pillar. Tighten Tighten the guide adjuster bracket retaining bolts to the pillar to 20 N.m (15 lb ft). 3. Align the tabs of the C-pillar side garnish molding trim with the openings in the pillar and push inward until fully seated. 4. Install the shoulder belt retaining bolt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to the guide adjuster bracket to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7711 5. Close the cover on the rear seat shoulder belt bolt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) Seat Belt Latch: Service and Repair Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) REMOVAL PROCEDURE 1. Remove the rear bench seat from the vehicle. 2. Remove the seat belt latch by removing the hog rings and lifting up on the cover to expose the nut. The complete seat cover does not have to be removed. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt latch nut. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the seat cover and rehog ring it back in place. 4. Install the rear bench seat to the vehicle. For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7716 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP7) REMOVAL PROCEDURE 1. Remove the seat belt buckle latch bolt from the side of the riser. 2. Remove the seat belt buckle latch. The seat does not have to be removed from the vehicle. INSTALLATION PROCEDURE 1. Install the seat belt buckle latch to the side of the riser. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle latch bolt. Tighten Tighten the seat belt buckle latch bolt to the riser to 35 N.m (26 lb ft). For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7717 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - Rear (RPO ZP8) REMOVAL PROCEDURE 1. Remove the rear bench seat side cover screw to expose the seat belt latch bolt. 2. Remove the rear bench seat side cover screw. 3. Remove the seat belt latch nut. 4. Remove the seat belt latch. INSTALLATION PROCEDURE 1. Install the seat belt latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt latch nut. Tighten Tighten the seat belt latch nut to 53 N.m (39 lb ft). 3. Install the rear bench seat side cover and screw. For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7718 Seat Belt Latch: Service and Repair Seat Belt Buckle and Latch Replacement - No.2 Rear REMOVAL PROCEDURE 1. Remove the rear seat form the vehicle. 2. Remove the seat belt buckle and latch retaining bolt from the seat frame. 3. Remove the seat belt buckle and latch through the seat back. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7719 1. Install the seat belt buckle and latch through the seat back. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat belt buckle and latch retaining bolt to the seat frame. Tighten Tighten the seat belt buckle and latch retaining bolt to 53 N.m (39 lb ft). 3. Install the rear bench seat in the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7720 Seat Belt Latch: Service and Repair Seat Belt Latch Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear seat from the vehicle. 2. Remove the seat belt latch retaining bolts from the seat frame. 3. Remove the seat belt latch retaining bolts from the seat frame. 4. Remove the seat belt latch through the seat back. 5. Remove the seat belt latch from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Service and Repair > Seat belt Buckle and Latch Replacement - Rear (RPO ZP5) > Page 7721 1. Install the seat belt latch to the vehicle through the seat back. 2. Install the seat belt latch to the vehicle through the seat back. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that hold the seat belt latch to the seat frame. Tighten Tighten the seat belt latch bolts to 53 N.m (39 lb ft). 4. Install the rear seat to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Fasten Safety Belt Indicator/Chime Inoperative Seat Belt Reminder Lamp: Testing and Inspection Fasten Safety Belt Indicator/Chime Inoperative Steps 1-4 Steps 5-11 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Fasten Safety Belt Indicator/Chime Inoperative > Page 7726 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection Seat Belt Retractor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Seat Belt Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front Seat Belt Retractor: Service and Repair Left Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the left inside garnish molding. 6. Remove the body side front lower molding. 7. Remove the electrical connectors. 8. Remove the bolt retaining the retractor from the pillar, lift upward to release. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7732 3. Install the electrical connectors. 4. Install the body side front lower molding. 5. Install the left inside garnish molding. 6. Install the bolt retaining the shoulder belt guide to the adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7733 Seat Belt Retractor: Service and Repair Right Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the right front lock pillar inside garnish molding. 6. Remove the cover on the base of the retractor to expose the bolt. 7. Remove the bolt from the retractor to the pillar. 8. Remove the electrical connectors. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. 2. Install the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7734 4. Install the cover to the base of the retractor. 5. Install the bolt retaining the shoulder belt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 6. Install the right front lock pillar inside garnish molding. 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7735 Seat Belt Retractor: Service and Repair Left Rear REMOVAL PROCEDURE 1. Remove the left rear bucket seat. 2. Remove the seat belt bolt from the rear floor. 3. Remove the body side trim panel. 4. Remove the cover from the shoulder belt to expose the bolt. 5. Remove the shoulder belt retaining bolt from the body side pillar. 6. Remove the retractor bolt from the body side panel. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7736 1. Install the retractor bolt to the body side panel. Tighten Tighten the retractor bolt to 53 N.m (39 lb ft). 2. Install the shoulder belt bolt to the body side pillar. Tighten Tighten the shoulder belt bolt to the body side pillar to 30 N.m (22 lb ft). 3. Install the cover to the shoulder belt. 4. Install the body side trim panel. 5. Install the seat belt bolt to the rear floor. Tighten Tighten the seat belt bolt to the rear floor to 53 N.m (39 lb ft). 6. Install the left rear bucket seat. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7737 Seat Belt Retractor: Service and Repair Right Rear REMOVAL PROCEDURE 1. Remove the trim cover from the rear seat belt retractor, by grasping the sides and pull downward. 2. Remove the seat belt retractor buckle from the latch. 2.1. Locate the red dot in the center of the buckle. 2.2. Insert a small pointed tool in the center of the buckle. 2.3. Push inward for it to release from the latch. 3. Remove the rear seat belt retractor nuts from the roof reinforcement. 4. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7738 1. Install the rear seat belt retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor nuts to the roof reinforcement panel. Tighten Tighten the seat belt retractor nuts to 35 N.m (26 lb ft). 3. Snap the retractor cover into place. 4. Install the seat belt buckle to the latch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7739 Seat Belt Retractor: Service and Repair Left Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the left inside garnish molding. 6. Remove the body side front lower molding. 7. Remove the electrical connectors. 8. Remove the bolt retaining the retractor from the pillar, lift upward to release. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7740 3. Install the electrical connectors. 4. Install the body side front lower molding. 5. Install the left inside garnish molding. 6. Install the bolt retaining the shoulder belt guide to the adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Right Front REMOVAL PROCEDURE 1. Slide the front seat all the way forward. 2. Remove the seat belt from the seat belt guide located on the side of the bucket seat. 3. Remove the cover from the shoulder belt guide to expose the bolt. 4. Remove the retaining bolt from the shoulder belt guide adjuster bracket. 5. Remove the right front lock pillar inside garnish molding. 6. Remove the cover on the base of the retractor to expose the bolt. 7. Remove the bolt from the retractor to the pillar. 8. Remove the electrical connectors. 9. Remove the retractor from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7741 1. Install the retractor to the vehicle. 2. Install the electrical connectors. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retractor bolt to the pillar. Tighten Tighten the retractor bolt to the pillar to 53 N.m (39 lb ft). 4. Install the cover to the base of the retractor. 5. Install the bolt retaining the shoulder belt to the guide adjuster bracket. Tighten Tighten the shoulder belt retaining bolt to 30 N.m (22 lb ft). 6. Install the right front lock pillar inside garnish molding. 7. Install the cover to the shoulder belt guide. 8. Install the seat belt to the seat belt guide located on the side of the bucket seat. 9. Slide the front seat back in position. Left Rear REMOVAL PROCEDURE 1. Remove the left rear bucket seat. 2. Remove the seat belt bolt from the rear floor. 3. Remove the body side trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7742 4. Remove the cover from the shoulder belt to expose the bolt. 5. Remove the shoulder belt retaining bolt from the body side pillar. 6. Remove the retractor bolt from the body side panel. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the retractor bolt to the body side panel. Tighten Tighten the retractor bolt to 53 N.m (39 lb ft). 2. Install the shoulder belt bolt to the body side pillar. Tighten Tighten the shoulder belt bolt to the body side pillar to 30 N.m (22 lb ft). 3. Install the cover to the shoulder belt. 4. Install the body side trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7743 5. Install the seat belt bolt to the rear floor. Tighten Tighten the seat belt bolt to the rear floor to 53 N.m (39 lb ft). 6. Install the left rear bucket seat. Right Rear REMOVAL PROCEDURE 1. Remove the trim cover from the rear seat belt retractor, by grasping the sides and pull downward. 2. Remove the seat belt retractor buckle from the latch. 2.1. Locate the red dot in the center of the buckle. 2.2. Insert a small pointed tool in the center of the buckle. 2.3. Push inward for it to release from the latch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7744 3. Remove the rear seat belt retractor nuts from the roof reinforcement. 4. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the rear seat belt retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear seat belt retractor nuts to the roof reinforcement panel. Tighten Tighten the seat belt retractor nuts to 35 N.m (26 lb ft). 3. Snap the retractor cover into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7745 4. Install the seat belt buckle to the latch. No. 2 Left Rear REMOVAL PROCEDURE 1. Remove the left rear storage trays. Squeeze the storage tray and pull upward to release. 2. Remove the shoulder belt cover to expose the bolt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7746 3. Remove the shoulder belt retaining bolt from the bracket. 4. Remove the retractor retaining bolt. 5. Remove the retractor from the vehicle. INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the retractor retaining bolt. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7747 3. Install the shoulder belt retaining bolt to the bracket. Tighten Tighten the shoulder belt retaining bolt to the bracket to 35 N.m (26 lb ft). 4. Install the retractor retaining bolt. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). 5. Install the storage trays. Squeeze the storage tray together. Press the storage tray into place. No. 2 Right Rear REMOVAL PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7748 1. Remove the jack storage access door. 2. Remove the storage tray. Squeeze the storage tray from underneath. This will expose the retractor bolt. 3. Remove the retractor retaining bolt. 4. Remove the shoulder belt cover to expose the bolt. 5. Remove the shoulder belt retaining bolt from the bracket. 6. Remove the retractor from the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7749 INSTALLATION PROCEDURE 1. Install the retractor to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolt retaining the shoulder belt to the bracket. Tighten Tighten the bolt retaining the shoulder belt to the bracket to 30 N.m (22 lb ft). 3. Install the shoulder belt cover. 4. Install the retractor retaining bolt. Tighten Tighten the retractor retaining bolt to 53 N.m (39 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7750 5. Install the storage tray. Squeeze the storage tray together. Press the storage tray into place. 6. Install the jack storage access door. Seat Belt Retractor Reinforcement Replacement - Left REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt anchor. 2. Remove the bolt retaining the rear seat shoulder belt anchor to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7751 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE 1. Install the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement bolts to 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement to the roof nuts to 35 N.m (26 lb ft). 4. Install the headliner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7752 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the rear seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the rear seat shoulder belt to the bracket bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt Seat Belt Retractor Reinforcement Replacement - Right REMOVAL PROCEDURE 1. Remove the cover from the rear seat shoulder belt. 2. Remove the bolt retaining the rear seat shoulder belt to the bracket. 3. Remove the rear seat shoulder belt bracket cover. 4. Remove the nut retaining the rear seat shoulder belt bracket to the reinforcement. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7753 5. Remove the headliner. 6. Remove the nuts retaining the rear seat shoulder belt reinforcement to the roof. 7. Remove the bolts retaining the rear seat shoulder belt reinforcement to the roof. 8. Remove the rear seat shoulder belt reinforcement from the roof. INSTALLATION PROCEDURE 1. Install the rear seat shoulder belt reinforcement to the roof. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement bolts to the roof 35 N.m (26 lb ft). 3. Install the nuts to retain the rear seat shoulder belt reinforcement to the roof. Tighten Tighten the rear seat shoulder belt reinforcement nuts to the roof to 35 N.m (26 lb ft). 4. Install the headliner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Left Front > Page 7754 5. Install the nut to retain the rear seat shoulder belt bracket to the reinforcement. Tighten Tighten the seat shoulder belt bracket to the reinforcement nut to 35 N.m (26 lb ft). 6. Install the rear seat shoulder belt bracket cover. 7. Install the bolt to retain the rear seat shoulder belt to the bracket. Tighten Tighten the seat shoulder belt bracket to the reinforcement bolt to 30 N.m (22 lb ft). 8. Install the cover to the rear seat shoulder belt bolt. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7759 Inflatable Restraint Front End Discriminating Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7760 Impact Sensor: Service Precautions CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7761 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END DISCRIMINATING SENSOR The front end discriminating sensor is equipped on some vehicles to supplement SIR system performance. The discriminating sensor is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the discriminating sensor to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7762 Impact Sensor: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Air Bag Systems / Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Discriminating Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Disconnect the mass air flow (MAF) and the intake air temperature (IAT) sensors harness connectors. 3. Loosen the clamp. 4. Remove the air tube from the throttle body air intake cover. 5. Remove the bolts. 6. Remove the upper radiator shroud. 7. Remove the fan and clutch assembly. 8. Remove the lower radiator shroud. 9. Disconnect the inflatable restraint front end discriminating sensor harness connector located at the top of the cradle (1). 10. Remove the bolts (2). 11. Remove the inflatable restraint front end discriminating sensor (3) from the cradle. INSTALLATION PROCEDURE CAUTION: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor: ^ Remove any dirt, grease, etc. from the mounting surface. ^ Position the sensor horizontally on the mounting surface. ^ Point the arrow on the sensor toward the front of the vehicle. ^ Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. 1. Install the inflatable restraint front end discriminating sensor to the top of the cradle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the inflatable restraint front end discriminating sensor mounting fasteners (2). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7765 Tighten Tighten fastener to 6.5 N.m (58 lb in). IMPORTANT: The following procedures should be utilized in the event that sensor mounting holes or fasteners are damaged to the extent that the sensor may no longer be properly mounted. 3. Perform the following steps in order to complete the first fastener repair; 3.1. Remove and discard the improperly installed rivet. 3.2. Reattach sensor with new rivet (GM P/N 15715058) or equivalent. 4. Perform the following steps, if needed, in order to complete a second fastener repair: 4.1. Remove the improperly installed rivet. 4.2. Enlarge the mounting holes in the lower radiator support to 9.0 mm (0.35 in). 4.3. Insert and properly seat rivnut (GM P/N 15699834) or equivalent. 4.4. Install sensor with screw GM P/N 11515664, or equivalent. Tighten Tighten fasteners to 6.5 N.m (58 lb in). 5. Connect the inflatable restraint front end discriminating sensor harness connector to the sensor. 6. Install the lower radiator shroud. 7. Install the fan and clutch assembly. 8. Install the upper radiator shroud. 9. Install the air box with MAF sensor to the upper radiator shroud. 10. Connect the air tube to the throttle body air intake cover with the clamp. 11. Connect the MAF and IAT sensors harness connectors. 12. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7766 Impact Sensor: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE CAUTION: ^ Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM: ^ Remove any dirt, grease, etc. from the mounting surface ^ Position the SDM horizontally on the mounting surface ^ Point the arrow on the SDM toward the front of the vehicle ^ Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. ^ If any water enters the vehicle's interior up to the level of the carpet or higher and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to be replaced. The SDM could be activated when powered, which could cause deployment of the air bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be disabled. Refer to Disabling the SIR System. With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant soaking or evidence of significant soaking is detected, you must perform the following tasks: 1. Remove all water. 2. Repair the water damage. 3. Replace the SDM harness connector. 4. Replace the SDM. Failure to follow these tasks could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. ^ Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. Refer to Air Bag(s) Arming and Disarming. 2. Remove the drivers seat. 3. Remove the carpet retaining sill trim molding. 4. Fold back the carpet to access the inflatable restraint sensing and diagnostic module (SDM). 5. Remove the connector position assurance (CPA) (1) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Push down the flex lock button (3) and slide the connector locking cover (4) to the open position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7767 7. Disconnect the SDM wiring harness connector (2) from the SDM (4). 8. Remove the SDM mounting fasteners (1). 9. Remove the SDM (4) from the vehicle (5). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) mounting studs and/or fasteners are damaged to the extent that the SDM may no longer be properly mounted. 10. Repair the fasteners using the following procedure: 10.1. Remove the stripped nut and discard the nut. 10.2. Drill out the weld spots to the weld stud from the floor pan side, then remove and discard the stud. 10.3. Condition the floor panel attaching surface where the new stud is to be installed. 10.4. Install new weld stud GM P/N 115115602 and clamp the weld stud. 10.5. Migweld the stud at the drilled holes form above or below the floor pan, as required. 10.6. Apply body sealer around any exposed openings. 10.7. Install a new fastener GM P/N 11515933. INSTALLATION PROCEDURE 1. Install the SDM (4) to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the SDM mounting fasteners (1). Tighten Tighten fasteners to 12 N.m (106 lb in). 3. Connect the SDM wiring harness connector (2) to the SDM (4). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7768 4. Push down the flex lock button (3) and slide the connector locking cover (4) to the close position. 5. Install the connector position assurance (CPA) (1) to the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector (2). 6. Position the carpet to cover the inflatable restraint sensing and diagnostic module (SDM). 7. Install the carpet retaining sill trim molding. 8. Install the driver seat. 9. Enable the SIR system. Refer to Air Bag(s) Arming and Disarming. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Discriminating Sensor Replacement > Page 7769 Impact Sensor: Service and Repair SIR Sensor Replacement Guidelines The SIR sensor replacement policy requires replacing sensors in the area of collision damage. The area of collision damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. ^ Replace the sensor even if the air bags have not deployed. ^ Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR sensing system. Do not try to determine whether the sensor is undamaged, replace the sensor. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7773 Seat Belt Buckle Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 7814 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7817 Accessory Delay Module: Reading and Clearing Diagnostic Trouble Codes With Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. With Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7818 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7819 Steps 1-10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7820 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7821 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the pan number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software pan number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7822 Scan Tool Data List Scan Tool Output Controls Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Service and Repair Antenna Mast: Service and Repair FIXED ANTENNA MAST REPLACEMENT REMOVAL PROCEDURE NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 1. Unscrew the antenna mast. 2. Remove the antenna mast from the antenna base. INSTALLATION PROCEDURE NOTE: Use tape on the tool surface so that you do not damage the paint on the antenna mast. 1. Install the antenna mast to the antenna base. NOTE: Refer to Fastener Notice in Service Precautions. 2. Secure the antenna mast to the antenna base. Tighten Tighten the antenna mast to 5.5 N.m (49 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-46-002A > Apr > 05 > OnStar(R) Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-46-002A > Apr > 05 > OnStar(R) Cellular Antenna Replacement Parts > Page 7840 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-08-46-003B > Feb > 05 > Instruments GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7850 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7867 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7872 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7873 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7879 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7896 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7901 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7902 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7907 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7912 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7913 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7914 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7915 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7916 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations > Page 7922 Antenna - Keyless Entry: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Remove the instrument panel cluster. 3. Disconnect the remote keyless entry antenna (1) from the receiver (2). 4. Remove the remote keyless entry antenna (1) from the carrier. 5. Remove the remote keyless entry antenna from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations > Page 7923 1. Install the remote keyless entry antenna to the vehicle. 2. Install the remote keyless entry antenna (1) to the carrier. 3. Connect the remote keyless entry antenna (1) to the receiver (2). 4. Install the instrument panel cluster. 5. Install the instrument panel cluster trim plate. 6. Reprogram the transmitter. Refer to Transmitter Programming. See: Testing and Inspection/Programming and Relearning 7. Verify that the system operates properly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 7927 Remote Control Door Lock Receiver (RCDLR) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 7928 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left knee bolster. 2. Disconnect the remote keyless entry antenna (2) from the receiver (5). 3. Disconnect the remote keyless entry electrical connector (4) from the receiver (5). 4. Remove the remote keyless entry module screws from the bracket (3). 5. Remove the remote keyless entry module from the carrier. INSTALLATION PROCEDURE 1. Install the remote keyless entry module to the carrier. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the remote keyless entry module screws to the bracket (3). Tighten Tighten the remote keyless entry module screws to the bracket (3) to 2 N.m (18 lb in). 3. Connect the remote keyless entry antenna (2) to the receiver (5). 4. Connect the remote keyless entry electrical connector (4) to the receiver (5). 5. Install the left knee bolster. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 7929 7. Verify that the system operates properly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery (2). INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 7934 1. Install the battery (2) with the positive (+) side down. Use one 3 V CR2032 battery (or the equivalent). 2. Close the transmitter case (6, 4). 3. Ensure the seal is in position. Align the 2 halves of the case and snap the two halves together. 4. Synchronize the transmitter. Refer to Transmitter Synchronization. 5. Replace the batteries when the range of the transmitter decreases to less than 7 m (23 ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Cellular Phone: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7946 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Cellular Phone: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7951 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Cellular Phone: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 7957 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Cellular Phone: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Cellular Phone: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 7970 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 02-08-46-004A > Apr > 06 > Cell Phone Error Messages, Bulletin Cancellation Cellular Phone: All Technical Service Bulletins Cell Phone - Error Messages, Bulletin Cancellation Bulletin No.: 02-08-46-004A Date: April 11, 2006 INFORMATION Subject: Cellular Error Messages Received When Trying to Connect to OnStar(R) Models: 2000-2002 Passenger Cars and Light Duty Trucks with Factory-Installed OnStar(R) Supercede: This bulletin is being revised to cancel this bulletin. The Subject information is addressed in Corporate Bulletin Number 03-08-46-004B. Please discard Corporate Bulletin Number 02-08-46-004 (Section 08 - Body & Accessories). Please reference Corporate Bulletin Number 03-08-46-004B for the Subject information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 01-08-46-004A > Mar > 05 > OnStar(R)/Cell Phone - Integration Cellular Phone: All Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Cellular Phone: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Cellular Phone: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 02-08-46-004A > Apr > 06 > Cell Phone Error Messages, Bulletin Cancellation Cellular Phone: All Technical Service Bulletins Cell Phone - Error Messages, Bulletin Cancellation Bulletin No.: 02-08-46-004A Date: April 11, 2006 INFORMATION Subject: Cellular Error Messages Received When Trying to Connect to OnStar(R) Models: 2000-2002 Passenger Cars and Light Duty Trucks with Factory-Installed OnStar(R) Supercede: This bulletin is being revised to cancel this bulletin. The Subject information is addressed in Corporate Bulletin Number 03-08-46-004B. Please discard Corporate Bulletin Number 02-08-46-004 (Section 08 - Body & Accessories). Please reference Corporate Bulletin Number 03-08-46-004B for the Subject information. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 01-08-46-004A > Mar > 05 > OnStar(R)/Cell Phone - Integration Cellular Phone: All Technical Service Bulletins OnStar(R)/Cell Phone - Integration Bulletin No.: 01-08-46-004A Date: March 08, 2005 INFORMATION Subject: Vehicle Integration of Cellular Phones and Normal Operating Characteristics Models: 2002 and Prior Passenger Cars and Trucks Supercede: This bulletin is being issued to cancel Corporate Bulletin Number 01-08-46-004. Please discard all copies of Corporate Bulletin Number 01-08-46-004 (Section 08 - Body and Accessories). This bulletin effectively cancels Corporate Bulletin Number 01-08-46-004. OnStar(R) no longer offers cellular phones as part of the OnStar(R) system. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8011 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8012 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8013 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8014 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8015 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Driver/Vehicle Information Display: Connector Views Ambient Air Temperature Sensor (DIC) Driver Information Center (DIC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Driver/Vehicle Information Display: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 8033 Driver/Vehicle Information Display: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8042 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8047 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8052 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8053 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8059 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8076 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8081 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8082 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter Programming Difficulties Garage Door Opener Transmitter: Customer Interest HomeLink(R) Transmitter - Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-08-97-002 > Nov > 01 > HomeLink(R) Transmitter - Programming Difficulties Garage Door Opener Transmitter: All Technical Service Bulletins HomeLink(R) Transmitter Programming Difficulties File In Section: 08 - Body and Accessories Bulletin No.: 01-08-97-002 Date: November, 2001 INFORMATION Subject: Programming the HomeLink(R) Transmitter Models: 2000-2002 Passenger Cars and Light Duty Trucks with Universal Garage Door Opener (RPO UG1) If you have customers that are having difficulties programming their HomeLink(R) transmitter, you may suggest the following options: ^ The customer may contact HomeLink(R) directly at 1-800-355-3515 for assistance. Assistance is available in English, French and Spanish languages. ^ The customer may also be directed to the HomeLink(R) website at www.homelink.com. The website is user-friendly and actively demonstrates how to program the transmitter. Many newer garage door openers have a "rolling code" feature and the website does a great job of guiding the owner through the entire programming process. The HomeLink(R) phone number, website address, and other useful information can also be found in Section 2 of the Owner's Manual under HomeLink(R) Transmitter. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8119 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8120 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8121 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8127 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8128 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Garage Door Opener Transmitter: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8129 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Technical Service Bulletins > Page 8130 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 Garage Door Opener Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 Garage Door Opener Schematics Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 8166 Garage Door Opener Transmitter: Application and ID Transmitter Reference Table Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 8167 Transmitter Reference Table Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 8168 Garage Door Opener Transmitter: Description and Operation The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of Radio Frequency Interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the Body Control Module (BCM). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices which could affect the operation of the garage door opener. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Garage Door Opener Inoperative Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8171 Steps 1-10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement REMOVAL PROCEDURE 1. Release the barbed tab at the center of the access panel. 2. Swing the panel down and forward in order to access the module. 3. Disconnect the electrical connector from the module and switch assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8174 4. Remove the screws that retain the garage door opener and the switch assembly to the console. 5. Remove the opener and the switch assembly from the console. INSTALLATION PROCEDURE 1. Align the LED indicator with the hole in the access panel when setting the opener into place. 2. Install the opener and the switch assembly to the console. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws that retain the opener and the switch assembly to the console. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8175 4. Connect the electrical connector to the opener and the switch assembly. 5. Swing the access panel up and rearward in order to close the access panel. 6. Snap the barbed tab into place in the console. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8176 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1,1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355- 3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer for the garage door opener (or call HomeLink(TM) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8177 Non-Compatible Garage Door Openers NON-COMPATIBLE GARAGE DOOR OPENERS Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 8178 Special Tools And Equipment Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8184 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8185 Global Positioning System Antenna: Technical Service Bulletins Onstar(R) - Antenna Coupling Revised Procedures File In Section: 08 - Body and Accessories Bulletin No.: 01-08-46-006A Date: December, 2001 SERVICE MANUAL UPDATE Subject: Revised OnStar(R) Antenna Coupling Replacement Procedures Models: 2000-2002 Passenger Cars and Trucks with Glass Mounted Antenna This bulletin is being revised to add the 2002 model year and revise the service procedures. Please discard Corporate Bulletin Number 01-08-46-006 (Section 08 - Body and Accessories). This bulletin is being issued to revise the OnStar(R) inner and outer antenna coupling replacement procedures in the Cellular Communication sub-section of the Body and Accessories section in the appropriate Service Manual. Please use the following to replace the existing information in the Service Manual. This information has been updated within SI2000. If you are using a paper version of this Service Manual, please mark a reference to this bulletin on the affected page in the Cellular Communication sub-section of the Service Manual. Coupling Replacement - Antenna Inner Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during the installation and for 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8186 1. Clean the inside of the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ On rear backglass applications the RF connections for the inner antenna coupling should run parallel to the defogger gridline. ^ Align the inner and the outer antenna couplings. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the inner antenna coupling. 5. Align the inner antenna coupling to the existing exterior coupling. 6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the glass (4). Hold pressure on the inner coupling (2) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Connect the coaxial cable to the inner coupling (2). 9. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60° F), for the adhesive to cure after installation. Coupling Replacement - Antenna Outer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8187 Removal Procedure Important: Use the described adhesion promoter to assure adequate bonding of the coupling to the glass. To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60° F) during the installation and for the 6-8 hours immediately following the installation. Otherwise the new couplings may come off. Also, disregard the drying or curing time information listed in the instructions included in the replacement antenna coupling kits. In the near future, those instructions will be updated with the drying or curing times listed in this bulletin. ^ Do not attempt to reinstall the original cellular couplings using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. Refer to Coupling Replacement - Antenna Inner. Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small, wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling. Installation Procedure 1. Clean the glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. Important: The glass adhesion promoter described in the next step must be used to ensure a bonding of the coupling to the glass surface. Failure to use the described adhesion promoter may result in the coupling coming off the glass. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8188 3. Apply Glass Adhesion Promoter, P/N 12378555 (in Canada, use P/N 88901239), to the glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. Important: ^ Align the outer antenna coupling with the inner coupling. ^ Do not touch the adhesive backing on the antenna coupling. 4. Remove the protective film from the adhesive backing on the outer antenna coupling. 5. Align the outer antenna coupling to the inner antenna coupling. 6. Press firmly on all 4 corners and on the center of the outer antenna coupling (5) in order to ensure proper adhesion to the glass (4). Hold pressure on the outer coupling (5) for 10 to 30 seconds. 7. Ensure that no gaps occur between the couplings (5, 2) and the glass (4). 8. Keep the vehicle dry. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the Driver Information Center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8193 Memory Positioning Systems: Description and Operation Vehicle Personalization PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission it left the factory programmed to lock all doors when the vehicle speed is greater than 24 km/h (15 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 second limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. ^ The following is a list of available programming options: ^ All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. ^ All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. ^ All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. ^ No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8202 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8207 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8213 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8222 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8231 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8232 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8233 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8234 Diagnostic Tips Review Table Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8235 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8236 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8237 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8238 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8239 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8240 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8241 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8242 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8243 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8244 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8245 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8246 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8247 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8248 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8265 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8279 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8288 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8289 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8290 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8291 Diagnostic Tips Review Table Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8292 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8293 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8294 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8295 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8296 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8297 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8298 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8299 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8300 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8301 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8302 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8303 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8304 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8305 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8326 Audio Amplifier Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8327 Amplifier: Service and Repair REMOVAL PROCEDURE 1. Remove the body side front lower trim panel. 2. Disconnect the electrical connector from the amplifier. 3. Remove the amplifier from the vehicle by sliding the amplifier toward the rear of the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8328 1. Align the mounting tabs and slide the amplifier toward the front of the vehicle in order to install the amplifier to the vehicle. 2. Connect the electrical connector to the amplifier. 3. Install the body front lower trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Locations Compact Disc Player (CD): Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Locations > Page 8332 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Locations > Page 8333 Remote Playback Device Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Locations > Page 8334 Compact Disc Player (CD): Service and Repair REMOTE CD PLAYER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel extension trim plate. 2. Squeeze the fasteners on both sides of the remote compact disc player. 3. Pull out the remote compact disc player. 4. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. 2. Align the fasteners on the remote compact disc player with the slots in the instrument panel extension. 3. Slide the remote compact disc player into place until the fasteners are fully seated. 4. Install the instrument panel extension trim plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations Speaker: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 8343 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 8344 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Page 8345 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions Speaker: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8348 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8349 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8350 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8351 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8352 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8353 Speaker: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8354 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8355 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8356 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8357 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8358 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8359 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8360 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8361 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8362 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8363 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8364 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8365 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Speaker: Connector Views Speaker - LF Door Speaker - LR Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Speaker - LF Door Tweeter Speaker - LR Door Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Speaker - LR Subwoofer Speaker - RF Door Tweeter Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Speaker - RF Door Speaker - RR Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Speaker - RR Door Speaker - RR Subwoofer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Speaker: Electrical Diagrams Radio/Audio System Schematics: Speakers And Sub-Woofers (Premium W/O RSA) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Radio/Audio System Schematics: Speaker And Sub-Woofer (Premium W/ RSA) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Base Level Speaker: Description and Operation Base Level BAL 1. Turn the BAL control knob behind the VOLUME knob to select more or less sound, distributed between the left or the right speakers. 2. The middle position will deliver an equal balance of sound between the left and right speakers. FADE 1. Turn the FADE control knob behind the TUNE knob to select more or less sound, distributed between the front and rear speakers. 2. The middle position will deliver an equal balance of sound between the front and rear speakers. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Base Level > Page 8388 Speaker: Description and Operation Uplevel BALANCE 1. Depress the BAL control in order to remove the control from the recessed position. 2. Rotate the balance to the right in order to adjust the sound to the right speakers. 3. Rotate the balance to the left in order to adjust the sound to the left speakers. 4. Push the control knob back in to store when not in use. FADE 1. Depress the FADE control in order to remove the control from the recessed position. 2. Rotate the FADE control knob to the right in order to adjust the sound to the front speakers. 3. Rotate the FADE control knob to the left in order to adjust the sound to the rear speakers. 4. Push the control knob back in order to store when not in use. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Speaker: Symptom Related Diagnostic Procedures Steps 1-9 Steps 1-2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8391 Steps 3-6 Steps 1-7 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8392 Steps 1-5 Steps 6-11 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8393 Steps 1-6 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8394 Steps 7-16 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower Speaker: Service and Repair Speaker Replacement - Front Lower REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the mounting screws. 3. Remove the speaker from the door. 4. Disconnect the electrical connector from the speaker. INSTALLATION PROCEDURE 1. Connect the electrical connector to the speaker. 2. Install the speaker to the door. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the speaker mounting screws. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the door trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower > Page 8397 Speaker: Service and Repair Speaker Replacement - Front Upper REMOVAL PROCEDURE 1. Remove the assist handle from the door. 2. Remove the retaining screw from the trim plate. 3. Remove the escutcheon from the trim plate. 4. Swing the plate down. 5. Remove the tweeter speaker from the trim plate by rotating in order to clear the mounting tabs. 6. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the tweeter speaker to the trim plate by rotating in order to lock the mounting tabs. 3. Verify component operation. 4. Swing the trim plate up. 5. Install the escutcheon to the trim plate. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the retaining screw to the trim plate. Tighten Tighten the trim plate screw to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower > Page 8398 7. Install the assist handle to the door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower > Page 8399 Speaker: Service and Repair Speaker Replacement - Rear Pillar REMOVAL PROCEDURE 1. Gently pry the rear speaker grille from the trim panel using a suitable flat-bladed tool. 2. Remove the speaker mounting screws. 3. Remove the rear speaker from the panel. 4. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the rear speaker to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the speaker mounting screws. Tighten Tighten the speaker mounting screws to 2 N.m (18 lb in). 4. Verify component operation. 5. Install the rear speaker grille to the trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower > Page 8400 Speaker: Service and Repair Speaker Replacement - Rear Door REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Remove the rivets that retain the speaker to the door. 3. Disconnect the electrical connector from the speaker. 4. Remove the speaker from the door. INSTALLATION PROCEDURE 1. Position the speaker to the door. 2. Connect the electrical connector to the speaker. 3. Install the speaker to the door. 4. Use a rivit gun in order to secure the speaker to the door with new rivets. 5. Install the door trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement - Front Lower > Page 8401 Speaker: Service and Repair Speaker Grille Replacement - Rear REMOVAL PROCEDURE 1. Open the rear door(s). 2. Separate the corners of the grille from the trim panel, one at a time, in order to remove the grille. 3. Remove the grille from the door trim panel. INSTALLATION PROCEDURE 1. Align the grill retaining clips with the slots in the door trim panel. 2. Seat the grille into place. 3. Close the door(s). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Audio System - Clearing `CLN' Message From Display Tape Player: Technical Service Bulletins Audio System - Clearing `CLN' Message From Display File In Section: 08 - Body and Accessories Bulletin No.: 01-08-44-006A Date: June, 2001 INFORMATION Subject: Cleaning the Cassette Tape Player and Clearing the CLN Message from the Radio Display Models: 1996-2002 Chevrolet and GMC Truck Models With Remote Cassette Tape Player (RP0 UP0) This bulletin is being revised to include additional model years and models, parts information, and to provide a procedure for cleaning the cassette tape player and resetting the CLN indicator on the radio display. Please discard Corporate Bulletin Number 01-08-44-006 (Section 08 - Body and Accessories). When the CLN message appears on the audio system, it indicates that the cassette tape player requires cleaning. Customers should follow the listed instructions. The recommended cleaning method for the remote cassette player is to use a scrubbing action, non-abrasive cleaning cassette, GM P/N 12344789. The cleaning cassette scrubs the tape head as the hubs of the cleaner cassette turn. Use the following procedure to clean the remote cassette player and reset the CLN indicator on the radio. 1. With the radio ON, insert the recommended cleaning cassette. 2. After a few seconds, the cleaning cassette may eject because it may appear to the player as a cassette with a broken tape. If ejection occurs, reinsert the cleaning cassette. Continue this process three or four times until the cleaning cassette is engaged for the time recommended by the cleaning cassette instructions. 3. Eject the cleaning cassette if the cassette does not eject on its own. 4. Press and hold the RECALL button on the radio until CLN appears on the radio display. While still pressing the radio RECALL button, press EJECT on the remote player. Release both buttons when the radio display indicates that the CLN indicator timer has been reset. Parts Information Parts are currently available from GMSPO. DISCLAIMER Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Page 8406 Tape Player: Service and Repair CASSETTE PLAYER CARE AND CLEANING TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Audio Kit If you do not regularly clean the tape player, the tape player is subject to the following conditions: ^ Reduced sound quality ^ Ruined cassettes ^ A damaged tape mechanism Cassette tapes may not operate properly if they are not stored in their cases away from the following conditions: ^ Contaminants ^ Direct sunlight ^ Extreme heat Cleaning Intervals Clean the cassette tape player after every 15 hours of operation for optimum performance. Clean the cassette tape player at a maximum of every 50 hours of playing time. This will prevent damage to the cassette tape player mechanism. The radio may display CLN, CLEAN, or CLEAN TAPE (depending on the type of radio being used), if equipped with the clean tape indicator feature. This indicates that you have used the tape player for 50 hours without resetting the tape clean timer. If this message appears on the display, clean the cassette tape player. The player can still play tapes but the player should be cleaned as soon as possible in order to prevent damage to the tapes and/or the player. Cassettes are subject to wear and the sound quality may degrade over time. If you notice a reduction in sound quality, play a different cassette. A new cassette may indicate whether the tape or the tape player is at fault. If the sound quality does not improve when the second tape is played, clean the cassette player. Perform this step regardless of when you last cleaned the cassette player. If a noticeable improvement is not achieved after cleaning the player, remove the radio assembly for repair. Head and Capstan Cleaning The following 2 components are cleaned on a cassette player: ^ The head ^ The capstan IMPORTANT: Do not contact the tape head with magnetized tools. If the head becomes magnetized, every cassette played in the player will be degraded. In order to properly clean a tape player, use the cleaning cassette in J 39916-A in order to clean the head and the capstan. The cleaning cassette is a scrubbing action, non-abrasive cassette with pads which scrub the tape head as the hubs of the cleaner cassette turn. When using a scrubbing action, non-abrasive cleaning, the cassette may eject. The unit is equipped with a cut tape detection feature. The feature than may detected as a broken tape. In order to prevent the cleaning cassette from being ejected, perform the following steps: 1. Turn the ignition switch to one of the following positions (depending upon the vehicle): ^ ON ^ RUN ^ ACC ^ ACCESSORY 2. Turn OFF the radio. 3. Press and hold the TAPE button for 5 seconds. The tape symbol on the display will flash for 2 seconds. 4. Insert the scrubbing action cleaning cassette. 5. Eject the cleaning cassette after the manufacturer's recommended cleaning time. When the cleaning cassette has been ejected, the cut tape detection feature is active again. The alternative method is to use a non-scrubbing action, wet type cleaning cassette. This cassette uses a fabric belt to clean the tape head. This type of cleaning cassette does not eject on its own. A non-scrubbing action cassette may not clean as thoroughly as the scrubbing type cleaning cassette. The use of this cassette is not recommended. After you clean the player, press and hold the EJECT button for 5 seconds to reset the CLEAN indicator. The radio display shows that the indicator has been reset. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 8443 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) POWER MODE RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The body control module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. If the ignition switch transitions from RUN/ON to OFF, the battery level is within the acceptable range and the passenger compartment doors are closed, the body control module closes the RAP relay. This provides power for the following: ^ Sunroof ^ Power windows ^ Power door locks ^ Radio ^ Rear radio ^ OnStar The BCM turns OFF the RAP function and opens the RAP relay when one of the following conditions are met: ^ The BCM senses the opening of any door or the liftgate. ^ The BCM detects a decrease in battery capacity below a prescribed limit. ^ The BCM receives a message from its internal timer indicating the end of the RAP period after 20 minutes. ^ The transition from OFF to RUN/ON or ACC of the ignition switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The Diagnostic System Check will provide the following information: ^ The identification of the control module which commands the system ^ The ability of the control module to communicate through the serial data circuit ^ The identification of any stored DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check TEST DESCRIPTION Steps 1-5 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. This step is checking for DTCs in the BCM. 5. This step is checking for RAP specific DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8446 Accessory Delay Module: Reading and Clearing Diagnostic Trouble Codes With Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. Without Scan Tool PROCEDURE Use a Tech II or equivalent Scan tool to clear Diagnostic Trouble Codes (DTCs) from the PCM memory. When clearing DTCs, follow the instructions supplied by the Scan tool manufacturer. NOTES: ^ Do not clear the DTCs unless directed to do so by the service information provided for each diagnostic procedure. All of the diagnostic data that was saved along with the DTC (freeze frame data and/or malfunction history records) which may be helpful for some diagnostic procedures will be erased from the memory when the DTCs are cleared. ^ Interrupting PCM battery voltage to clear DTCs is NOT recommended. With Scan Tool PROCEDURE A Tech II or equivalent Scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the Scan tool manufacturer in order to access and read either current and/or history DTCs. Without Scan Tool A Tech II or equivalent scan tool must be used to retrieve Diagnostic Trouble Codes (DTCs) from the PCM memory. DTCs can no longer be retrieved at the data link connector. This also eliminates the PCM function of flashing Code 12. Follow the instructions supplied by the scan tool manufacturer in order to access and read either current and/or history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8447 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms IMPORTANT PRELIMINARY CHECKS BEFORE STARTING 1. Perform the Diagnostic System Check - Accessory Delay Module before using the Symptom Tables in order to verify that all of the following are true: ^ There are no DTCs set. ^ The control module(s) can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. VISUAL/PHYSICAL INSPECTION ^ Inspect for aftermarket devices which could affect the operation of the Retained Accessory Power system. Refer to Checking Aftermarket Accessories in Diagnostic Aids. ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. INTERMITTENT Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagnostic Aids. SYMPTOM LIST Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: ^ Retained Accessory Power (RAP) On After Timeout ^ Retained Accessory Power (RAP) Inoperative Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8448 Steps 1-10 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8449 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8450 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions MODULE INFORMATION 1 Julian Date of Build: The scan tool displays the date upon which the Body Control Module (BCM) was manufactured. Manufacture Enable Counter (MEC): The scan tool displays the actual value for the MEC in the BCM. This information is for the assembly plant only. Module Part Number: The scan tool displays the pan number assigned to the BCM that is currently in the vehicle. Software Design Suffix: The scan tool displays the version of the software pan number in the BCM. Software Part Number: The scan tool displays the software identification number (ID) in the BCM. MODULE INFORMATION 2 Retained Accessory Power (RAP) Calibration Number: The scan tool displays the RAP calibration part number in the BCM. Retained Accessory Power (RAP) Suffix: The scan tool displays the RAP identification number in the BCM. DATA Battery Voltage: The scan tool displays the battery system voltage. Inadvertent Power Timer: The scan tool displays the seconds left before the BCM turns the inadvertent power relay OFF. The BCM uses this feature to protect the battery against inadvertent battery rundown caused by components that are part of the courtesy lamp circuit. The inadvertent power relay is supplied power by the BCM for 2400 seconds / 40 minutes after the ignition is turned OFF. RAP Timer: The scan tool displays the seconds left before the BCM turns the RAP relay OFF. The BCM uses this feature to allow the operation of the radio and the power windows for up to 1198 seconds / 20 minutes after the ignition is turned OFF. After the time has elapsed or the door is opened the BCM will open the ground circuit for the RAP relay. INPUT 1 Door Handle Switch: The scan tool displays the position of the door handle. The scan tool displays ACTIVE when a door handle is raised and INACTIVE with all doors closed and the door handles at rest. Drivers Door Jamb Switch: The scan tool displays the position of the drivers door. The scan tool displays ACTIVE when the drivers door is open. Ignition 1: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN or CRANK position. Ignition 3: The scan tool displays the position of the ignition switch. The scan tool displays ACTIVE when the ignition switch is in the RUN position only. Ignition Power Mode: The scan tool displays the position of the ignition switch. The scan tool displays OFF, RUN, CRANK and UNKNOWN. The UNKNOWN display is when the BCM can not determine the position of the ignition switch. Key In Ignition: The scan tool displays the position of the ignition key in the ignition switch cylinder. The scan tool displays YES when the ignition key is completely inserted into the ignition switch cylinder. The BCM uses this data in controlling the operation of the reminder chime feature. RAP Relay Feedback: The scan tool displays the state of the RAP relay. The scan tool displays ON when the BCM activates the RAP relay. OUTPUTS RAP Relay: The scan tool displays the commanded state of the RAP relay. The scan tool displays ON when the BCM allows the RAP relay to go to ground. The BCM will allow operation of the radio and the power windows with the ignition OFF and the doors closed for up to 1198 seconds, approximately 20 minutes. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8451 Scan Tool Data List Scan Tool Output Controls Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8460 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8465 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8470 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8471 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8477 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8494 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8499 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8500 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8522 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8523 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8524 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8530 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8531 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8532 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8541 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8542 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 8543 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8549 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8550 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 8551 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the hitch from the frame nuts. 3. Remove the hitch to frame bolts. 4. Remove the hitch and bumper from the vehicle. 5. Remove the hitch to bumper nuts. 6. Remove the hitch to bumper bolts. 7. Remove the hitch from the bumper. Installation Procedure 1. Install the hitch to the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hitch to bumper bolts. Tighten the hitch to bumper bolts to 35 N.m (26 lb ft). 3. Install the hitch to bumper nuts. Tighten the hitch to bumper nuts to 25 N.m (18 lb ft). 4. Install the hitch and the bumper to the vehicle. 5. Install the hitch to frame nuts. Tighten the hitch to frame nuts to 60 N.m (44 lb ft). 6. Install the hitch to frame bolts. Tighten the hitch to frame bolts to 55 N.m (41 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8564 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8571 Body Control Module C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 8572 Body Control Module C3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Page 8573 Body Control Module: Description and Operation The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures IMPORTANT: If any module is replaced, programming the module with the proper RPO configurations must be done prior to performing the Passlock Learn procedure. 1. The BCM must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options. If the BCM is not properly configured with the correct RPO codes the BCM will not control the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: ^ The battery is fully charged. ^ The ignition switch is in the RUN position. ^ The DLC is accessible. ^ All disconnected modules and devices are reconnected before programming. 2. Follow the SPS instructions on the Techline Terminal and scan tool to program the BCM. 3. If the BCM fails to accept the program, perform the following steps: ^ Inspect all BCM connections. ^ Verify that the SPS Techline Terminal and scan tool have the latest software version. Passlock Learn Procedures Refer to the Theft Deterrent sub-system for the appropriate learn procedure. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve History DTCs from all modules. 5. Clear all history DTCs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8576 Body Control Module: Removal and Replacement REMOVAL PROCEDURE Replacing the body control module (BCM) may be necessary when you service the body control system. IMPORTANT: The ignition switch should be in the OFF position when connecting or disconnecting the connectors to the BCM. Always disconnect the Brown BCM connector FIRST and connect the Brown BCM connector LAST. The BCM can set DTC(s) with the ignition switch in the OFF position. The BCM has battery run down protection for the courtesy lamp circuit. The BCM battery run down protection can not detect shorts on inputs or other circuits which it does not control. The scan tool can be used to put the BCM to sleep in order to check for current draws on circuits which are not controlled by the BCM or controlled by the battery run down protection system. If an excessive current draw is detected, refer to Battery Electrical Drain/Parasitic Load Test (w/ BCM) in Starting and Charging. 1. Remove the radio from the vehicle. 2. Remove the heater control. Pull the heater control (2) out and down in order to gain access to the body control module. 3. Push upward on the bracket retainer slightly and pull the body control module (2) from the bracket (1) at an angle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8577 4. Disconnect the electrical connectors (2) from the body control module (1). 5. Remove the body control module from the vehicle. INSTALLATION PROCEDURE 1. Install the body control module (2) to the vehicle. 2. Install the body control module to the bracket (1) at an angle under the wide hook retainer, with the label facing away from the bracket. 3. Apply pressure on the center of the body control module in order to move the module toward the mounting bracket base. Snap the module into place. 4. Ensure that the module is fully seated. Ensure that both snap retainers are holding the module. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 8578 5. Connect the electrical connectors (2) to the body control module (1). 6. Install the heater control (2). 7. Install the radio to the vehicle. 8. Use the following components in order to program the body control module with the proper calibrations: ^ The Techline Terminal ^ The Scan Tool 9. Perform the body control module programing. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning 10. Clear the diagnostic trouble codes (DTCs). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures Access Cover: Procedures Engine Cover ENGINE COVER Removal Procedure 1. Remove the instrument panel extension. Refer to "Instrument Panel Extension". 2. Remove the floor air outlet duct. Refer to "Air Outlet - Center Floor". 3. Remove the bolts from the brackets: ^ Loosen the bolt. ^ Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8583 6. Remove the engine cover. Installation Procedure 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. 3. Install the latch screws. Tighten Tighten the latch screws to 4 Nm (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten Tighten the engine cove bolt to 25 Nm (18 lb ft). 5. Insert the floor air outlet duct. 6. Insert the instrument panel extension. Instrument Panel (IP) Extension INSTRUMENT PANEL (I/P) EXTENSION REPLACEMENT REMOVAL PROCEDURE 1. Remove the caps that cover the extension screws. 2. Remove the screws from the extension. 3. Remove the nuts at the bottom of the extension. 4. Pull toward the rear of the vehicle in order to remove the extension from the instrument panel. 5. Disconnect the electrical connectors. INSTALLATION PROCEDURE 1. Connect the electrical connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8584 2. Install the extension to the instrument panel: 2.1. Align the retainers. 2.2. Press the extension into place until the retainers are seated. 3. Install the nuts that retain the extension to the floor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts that retain the extension to the floor to 8 Nm (71 lb in). 4. Install the retaining screws. Tighten Tighten the screws to 8 Nm (71 lb in). 5. Install the extension screw covers. Air Outlet - Center Floor AIR OUTLET REPLACEMENT - CENTER FLOOR REMOVAL PROCEDURE 1. Remove the IP extension. Refer to "Instrument Panel (I/P) Extension". 2. Remove the floor air outlet duct from the air distributor. 3. Remove the bucket seats. Refer to "Seat Replacement Bucket". 4. Remove the front section of the carpet, if equipped. Refer to "MAT/Carpet Replacement". Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8585 5. Remove the retaining nuts from the floor outlet duct, if equipped. 6. Remove the floor air outlet from the ducts to the rear seat, if equipped. INSTALLATION PROCEDURE 1. Install the floor air outlet to the ducts to the rear seat, if equipped. 2. Install the retaining nuts to the floor outlet duct, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8586 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 2 Nm (18 lb in). 3. Install the front section of the carpet, if equipped. 4. Install the bucket seats. 5. Install the floor air outlet duct from the air distributor. 6. Install the IP extension. Engine Cover Guide Assembly ENGINE COVER GUIDE ASSEMBLY Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement. 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly from the vehicle. Installation Procedure 1. Install the engine cover guide assembly. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten Tighten the bolts that retain the engine cover guide to 8.5 Nm (75 lb in). 3. Install the engine cover. MAT/Carpet Replacement MAT/CARPET REPLACEMENT - FRONT FLOOR REMOVAL PROCEDURE 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket. 2. Remove the engine cover, if required. Refer to Engine Cover Replacement. 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement. 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8587 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 9. Remove the carpet/mat from the vehicle. INSTALLATION PROCEDURE CAUTION: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. NOTICE: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. TIGHTEN Screws to 2 Nm (18 lb. in.). 4. Install the front side door lock pillar garnish molding, if required. Refer to Garnish Molding Replacement - LF Lock Pillar. 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement. 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side. 7. Install the engine cover, if required. Refer to Engine Cover Replacement. 8. Install the seats and the risers. Refer to Seat Replacement - Bucket in Seats. Seat Replacement - Bucket SEAT REPLACEMENT - BUCKET REMOVAL PROCEDURE 1. Remove the seat belt from the side of the seat belt guide. 2. Remove the nuts that retain the seat to the floor. 3. Disconnect the electrical connector from the power seat if equipped. 4. Remove the seat and the riser from the vehicle. 5. Remove the seat belt guide from the seat riser. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8588 6. Remove the bolts that retain the seat to the riser. 7. Remove the power seat from the seat risers if equipped. 8. Remove the manual seat adjuster wire from the seat tracks. 9. Remove the seat riser spacer nuts and bolts from the seat tracks. 10. Remove the seat riser spacer from the seat risers. INSTALLATION PROCEDURE 1. Install the seat riser spacer to the seat risers. 2. Install the seat riser spacer nuts and bolts to the seat tracks. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat riser spacer nuts and bolts to the seat tracks to 30 Nm (22 lb ft). 3. Install the manual seat adjuster wire to the seat tracks. 4. Install the power seat to the seat risers if equipped. 5. Install the seat belt guide to the seat riser. 6. Install the nuts that retain the seat to the risers. Tighten Tighten the nuts that retain the seat to the riser to 43 Nm (32 lb ft). 7. Install the seat and the seat riser in the vehicle. 8. Connect the electrical connector to the power seat if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8589 9. Install the nuts that retain the seat to the floor. Tighten Tighten the nuts that retain the seat to the floor to 43 Nm (32 lb ft). 10. Install the seat belt to the side of the seat belt guide. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8590 Access Cover: Removal and Replacement Engine Cover Replacement Engine Cover Replacement Removal Procedure 1. Remove the instrument panel extension. Refer to IP Extension Replacement (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/IP Extension Replacement) in Instrument Panel, Gages and Console. 2. Remove the floor air outlet duct. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. 3. Remove the bolts from the brackets: 1. Loosen the bolt. 2. Rotate the bracket out of the way. 4. Remove the latches. 5. Remove the screws. 6. Remove the engine cover. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8591 1. Install the engine cover. 2. Install the screws to the engine cover. Do not fully tighten the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the latch screws. Tighten the latch screws to 4 N.m (35 lb in). 4. Install the engine cover bolts to the brackets. Tighten the engine cover bolt to 25 N.m (18 lb ft). 5. Insert the floor air outlet duct. Refer to IP Extension Replacement (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/IP Extension Replacement) in Instrument Panel, Gages and Console. 6. Insert the instrument panel extension. Refer to Air Outlet Replacement - Center Floor in Heating, Ventilation and Air Conditioning. Engine Cover Guide Replacement Engine Cover Guide Replacement Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Access Cover, Engine > Component Information > Service and Repair > Procedures > Page 8592 Removal Procedure 1. Remove the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . 2. Remove the bolts that retain the engine cover guide assembly to the vehicle. 3. Remove the engine cover guide assembly. Installation Procedure 1. Install the engine cover guide assembly. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the engine cover guide assembly to the vehicle. Tighten the bolts that retain the engine cover guide to 8.5 N.m (75 lb in). 3. Install the engine cover. Refer to Engine Cover Replacement (See: Engine Cover Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front Auxiliary Step / Running Board: Service and Repair Assist Step Extension Replacement - Front Assist Step Extension Replacement - Front Removal Procedure 1. Remove the screws from the front edge of the assist step. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it fully releases from the assist step plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8597 7. Remove the front section of the assist step as follows: 1. Lift in the center of the assist step. 2. Slide the front section forward. 3. Lift upward on the assist step to release from the retainer. 8. Remove the nut and bolt (1) from the front assist step support bracket to the pinchweld flange. 9. Remove the assist step support bracket bolts (2) from the underbody. 10. Remove the assist step support bracket. Installation Procedure 1. Install the assist step support bracket. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step support bracket bolts (2) to the underbody . Tighten the assist step support bracket bolts (2) to the underbody to 25 N.m (18 lb ft). 3. Install the nut and bolt (1) to the assist step support bracket and to the pinchweld flange. Tighten the nut and bolt (1) to the assist step support bracket and to the pinchweld flange to 10 N.m (89 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8598 4. Use the following procedure when installing the assist step: 1. Check the fit to the step well and the door opening. 2. Check the height and the alignment to rocker panel. 3. Check the alignment to the cladding and to the body. 4. Check the gaps between the wheel well moldings. 5. Check the lower edge of the assist step to ensure a even gap along the door edge and the body. 6. Install the front section of the assist step to fit over the rear section. Align both sections before installing the nuts to the assist step pad. 5. Install the assist step pad to assist step. Align the assist step pad to the assist step and press downward until fully seated. 6. Install the nuts to the assist step pad by hand. Tighten the nuts to the assist step pad to 2 N.m (18 lb in). 7. Install the nut to the front lower corner of the assist step. Tighten the nut to the front lower corner of the assist step to 10 N.m (89 lb in). 8. Lower the vehicle to a suitable height. 9. Install the push clips to the front edge of the assist step. 10. Install the screws to the front edge of the assist step. Open the door to expose the inner screw. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8599 Tighten the screws to the upper and inner edges of the assist step to 2 N.m (18 lb in). 11. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8600 Auxiliary Step / Running Board: Service and Repair Assist Step Plate Replacement Assist Step Plate Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 3. Remove the nuts that attach the assist step plate to the assist step support bracket. 4. Remove the assist step plate. Installation Procedure 1. Install the assist step plate. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts that attach the assist step plate to the support bracket. Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 3. Install the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8601 Auxiliary Step / Running Board: Service and Repair Assist Step Support Brace Replacement Assist Step Support Brace Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step brace. 2. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 3. Remove the assist step brace. Installation Procedure 1. Install the assist step brace. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 3. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8602 Auxiliary Step / Running Board: Service and Repair Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step support bracket. 2. Remove the nuts that attach the assist step plate to the assist step support bracket. 3. The assist step support brackets are to be numbered 1 through 5 in the order when removing. 4. Remove the nuts and bolts (1) that attach the assist step plate to the assist step bracket. 5. Remove the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. 6. Remove the assist step support bracket from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8603 1. Install the assist step support bracket to the vehicle. 2. Install the assist step support brackets 1 through 5 in the order which they were removed. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. Tighten the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody to 25 N.m (18 lb ft). 4. Install the nuts and bolts (1) that attach the assist step brace to the assist step bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step bracket to 10 N.m (89 lb in). 5. Install the nuts that attach the assist step plate to the assist step support bracket. Tighten the nuts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8604 Auxiliary Step / Running Board: Service and Repair Assist Step Extension Replacement - Front Assist Step Extension Replacement - Front Removal Procedure 1. Remove the screws from the front edge of the assist step. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it fully releases from the assist step plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8605 7. Remove the front section of the assist step as follows: 1. Lift in the center of the assist step. 2. Slide the front section forward. 3. Lift upward on the assist step to release from the retainer. 8. Remove the nut and bolt (1) from the front assist step support bracket to the pinchweld flange. 9. Remove the assist step support bracket bolts (2) from the underbody. 10. Remove the assist step support bracket. Installation Procedure 1. Install the assist step support bracket. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step support bracket bolts (2) to the underbody . Tighten the assist step support bracket bolts (2) to the underbody to 25 N.m (18 lb ft). 3. Install the nut and bolt (1) to the assist step support bracket and to the pinchweld flange. Tighten the nut and bolt (1) to the assist step support bracket and to the pinchweld flange to 10 N.m (89 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8606 4. Use the following procedure when installing the assist step: 1. Check the fit to the step well and the door opening. 2. Check the height and the alignment to rocker panel. 3. Check the alignment to the cladding and to the body. 4. Check the gaps between the wheel well moldings. 5. Check the lower edge of the assist step to ensure a even gap along the door edge and the body. 6. Install the front section of the assist step to fit over the rear section. Align both sections before installing the nuts to the assist step pad. 5. Install the assist step pad to assist step. Align the assist step pad to the assist step and press downward until fully seated. 6. Install the nuts to the assist step pad by hand. Tighten the nuts to the assist step pad to 2 N.m (18 lb in). 7. Install the nut to the front lower corner of the assist step. Tighten the nut to the front lower corner of the assist step to 10 N.m (89 lb in). 8. Lower the vehicle to a suitable height. 9. Install the push clips to the front edge of the assist step. 10. Install the screws to the front edge of the assist step. Open the door to expose the inner screw. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8607 Tighten the screws to the upper and inner edges of the assist step to 2 N.m (18 lb in). 11. Lower the vehicle. Assist Step Plate Replacement Assist Step Plate Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 3. Remove the nuts that attach the assist step plate to the assist step support bracket. 4. Remove the assist step plate. Installation Procedure 1. Install the assist step plate. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts that attach the assist step plate to the support bracket. Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 3. Install the front and rear assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Assist Step Support Brace Replacement Assist Step Support Brace Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step brace. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8608 2. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 3. Remove the assist step brace. Installation Procedure 1. Install the assist step brace. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 3. Lower the vehicle. Assist Step Support Bracket Replacement Assist Step Support Bracket Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step assembly does not have to be removed to replace the assist step support bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8609 2. Remove the nuts that attach the assist step plate to the assist step support bracket. 3. The assist step support brackets are to be numbered 1 through 5 in the order when removing. 4. Remove the nuts and bolts (1) that attach the assist step plate to the assist step bracket. 5. Remove the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. 6. Remove the assist step support bracket from the vehicle. Installation Procedure 1. Install the assist step support bracket to the vehicle. 2. Install the assist step support brackets 1 through 5 in the order which they were removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8610 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody. Tighten the bolts (2) that attach the assist step plate to the assist step support bracket to the underbody to 25 N.m (18 lb ft). 4. Install the nuts and bolts (1) that attach the assist step brace to the assist step bracket Tighten the nuts and bolts (1) that attach the assist step brace to the assist step bracket to 10 N.m (89 lb in). 5. Install the nuts that attach the assist step plate to the assist step support bracket. Tighten the nuts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 6. Lower the vehicle. Assist Step Support Retainer Replacement Assist Step Support Retainer Replacement Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the assist step extension. Refer to Assist Step Replacement (See: Assist Step Replacement) . Important: Do not use a sharp tool in the removal of the assist step retainer, It will damage the paint. Use a plastic tool to assist in the removal of the assist step retainer. 3. Remove the assist step retainer screws from the rocker panel. 4. Insert a plastic tool along the edge of the retainer to aid in the removal. 5. Remove the assist step retainer. The right side is a one piece retainer, the left side is a two piece retainer. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8611 1. Install the assist step retainer to the rocker panel. The right side is a one piece retainer, the left side is a two piece retainer . 1. Clean the rocker panel with isopropyl cleaner or equivalent to remove all of the old double back tape. 2. Remove the strip from the double sided adhesive tape. 3. Align the assist step retainer to the rocker panel and press firmly in place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step retainer screws to the rocker panel. Tighten the assist step retainer screws to the rocker panel to 2 N.m (18 lb in). 3. Install the assist step extensions. Refer to Assist Step Replacement (See: Assist Step Replacement) . 4. Lower the vehicle. Assist Step Rear Anchor Replacement Assist Step Rear Anchor Replacement Removal Procedure 1. Raise the vehicle to a suitable height. Important: The assist step does not have to be removed to replace the assist step support bracket. 2. Remove the nuts that attach the assist step plate to the assist step support bracket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8612 3. Remove the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. 4. Remove the nuts and bolts that attach the rear assist step support bracket to the in rocker panel. 5. Remove the assist step support bracket from the vehicle. 6. Remove the nuts and bolts from the rear anchor that attach to the inner pinchwell flange and to the inner rocker panel. 7. Remove the rear anchor from the vehicle. Installation Procedure 1. Install the rear anchor to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8613 2. Install the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Tighten the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel to 25 N.m (18 lb ft). 3. Install the assist step support bracket to the vehicle. 4. Install the nuts and bolts that attach the rear assist step support bracket to the inner rocker panel. Tighten the nuts and bolts that attach the rear assist step support bracket to the inner rocker panel to 25 N.m (18 lb ft). 5. Install the nuts and bolts (1) that attach the assist step brace to the assist step support bracket. Tighten the nuts and bolts (1) that attach the assist step brace to the assist step support bracket to 10 N.m (89 lb in). 6. Install the nuts and bolts that attach the assist step plate to the assist step support bracket. Tighten the nuts and bolts that attach the assist step plate to the assist step support bracket to 10 N.m (89 lb in). 7. Lower the vehicle. Assist Step Replacement Assist Step Replacement Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8614 Removal Procedure 1. Remove the screws from the front edge of the assist step extension. Open the door to expose the inner screw. 2. Remove the push clips from the front edge of the assist step extension. 3. Raise the vehicle to a suitable height. 4. Remove the nut from the front lower corner of the assist step extension. 5. Remove the assist step pad nuts. 6. Remove the assist step pad. 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it is fully released from the assist step plate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8615 7. Remove the front section of the assist step extension as follows: 1. Lift in the center of the assist step extension. 2. Slide the front section forward. 3. Lift upward on the assist step extension to release it from the retainer and assist plate. 8. Remove the screws from the right rear inner and outer wheel well. Open the sliding door to expose the inner screw. 9. Remove the screws from the rear outer edge of the assist step extension. If the vehicle is equipped with assist steps, the cladding is shorter on the left side (bottom edge). 10. Remove the rear section of the assist step extension, by lifting upward until fully released from the retainer. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8616 11. Remove the nuts that attach the assist step plate to the assist step support bracket . 12. Remove the bolt (1) from the assist step support brace. 13. The assist step support brackets are to be numbered (1, 2, 3, 4, 5) when removing. 14. Remove the bolts (2) from the underbody. 15. Remove the assist step support bracket . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8617 16. Remove the nuts and bolts from the rear assist step support bracket. 17. Remove the rear assist step support bracket. 18. Remove the nuts and bolts from the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Important: Do not use a sharp tool in the removal of the assist step retainer, it will damage the paint. Use a plastic tool to assist in the removal of the assist step retainer. The assist step retainer is held in place by a double backing tape. 19. Remove the screws from the assist step retainer. The right side is a one piece retainer, the left side is a two piece retainer. 20. Remove the assist step retainer from the rocker panel. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8618 1. Install the assist step retainer to the rocker panel. The right side is a one piece retainer, the left side is a two piece retainer. 1. Clean the rocker panel with isopropyl cleaner or equivalent to remove all of the old double backing tape. 2. Remove the strip from the double back tape if replacing retainer. 3. Align the assist step retainer to the holes in the rocker panel and press in place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to the assist step retainer. Tighten the screws to the assist step retainer to 2 N.m (18 lb in). 3. Install the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel. Tighten the nuts and bolts to the rear anchor that attaches to the inner pinchwell flange and to the inner rocker panel to 25 N.m (18 lb ft). 4. Install the rear assist step support bracket. 5. Install the nuts and bolts to the rear assist step support bracket. Tighten the nuts and bolts to rear assist step support bracket to 25 N.m (18 lb ft). 6. Lay out the assist step support brackets in the order in which they were removed (1, 2, 3, 4, 5). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8619 7. Install the assist step support brackets and bolts (2) to the underbody. Tighten the assist step support bracket and bolts (2) to the underbody to 25 N.m (18 lb ft). 8. Install the bolt from the inside of the pinchweld flange. 9. Install the assist step support brace bolt (1) to the pinchweld flange. Tighten the assist step support brace bolt (1) to the pinchweld flange to 10 N.m (89 lb in). 10. Install the nuts that attach the assist step plate to the support bracket . Tighten the nuts that attach the assist step plate to the support bracket to 10 N.m (89 lb in). 11. When installing the assist step, check the height and the alignment to rocker panel, cladding and to the body. 12. Install the rear section of the assist step extension. Align the rear edge of assist step extension with the rear edge of the retainer and pushing downward until fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8620 13. Install the screws to the rear outer edge of the assist step extension. If the vehicle is equipped with running boards, the cladding will be shorter on the left side only. Tighten the screws to the rear outer edge of the assist step extension to 2 N.m (18 lb in). 14. Install the screws to the right rear inner and outer wheel well. Open the sliding door to expose the inner screw. Tighten the screws to the right rear inner and outer wheel well to 2 N.m (18 lb in). Important: Use the following steps when installing the assist step extensions to the retainer: * Check to ensure that the front assist step extension fits over the center of the rear extension. * Check for a suitable fit to the step well and the door opening. * Check the height and the alignment to the rocker panel and to the door opening. * Check the alignment to the cladding and to the body. * Check the alignment gaps between the wheel well molding and body. * Check the lower edge of the assist step extensions to ensure an even gap along the lower edge of the body. 15. Install the assist step extensions to the retainer. 16. Install the nut to the front lower corner of the assist step extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8621 Tighten the nut to the front lower corner of the assist step extension to 10 N.m (89 lb in). 17. Lower the vehicle to a suitable height. 18. Install the screws to the front assist step extension. Open the door to expose the inner screw. Tighten the front assist step extension screws to 2 N.m (18 lb in). 19. Install the push clips to the front edge of the assist step extension. 20. Install the screws to the front edge of the assist step extension. Tighten the screws to the front edge of the assist step extension to 7 N.m (62 lb in). 21. Install the assist step pad. 22. Align the assist step pad to the assist step plate and press downward firmly until fully seated. The nuts are to be hand torqued. 23. Install the assist step pad nuts. Tighten the assist step pad nuts to 2 N.m (18 lb in). 24. Lower the vehicle. Assist Step Pad Replacement Assist Step Pad Replacement Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8622 Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the assist step pad nuts. 3. Remove the assist step pad as follows: 1. Insert a plastic tool along the edge. 2. Pull upward on the assist step pad until it is fully released from the assist step plate. Installation Procedure 1. Install the assist step pad as follows: 1. Align the assist step pad to the assist step plate and press downward firmly until seated. 2. The assist step pad nuts are to be hand torque. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist step pad nuts Tighten the assist step pads nuts to 8 N.m (9 lb in). 3. Lower the vehicle. Assist Step Extension Replacement - Rear Assist Step Extension Replacement - Rear Removal Procedure 1. Raise the vehicle to a suitable height. 2. Remove the front section of the assist step extension. Refer to Assist Step Plate Replacement (See: Assist Step Plate Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8623 3. Remove the screws from the left rear outer edge of the assist step extension. 4. Lift upward on the assist step extension until fully released from the retainer. 5. Remove the screws from the right rear inner and outer wheel well. 6. Open the sliding door to expose the screw. 7. Lift upward on the assist step extension until fully released from the retainer. 8. Remove the rear section of the assist step extension. Installation Procedure Important: Use the following procedure when installing the assist step extension: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair > Assist Step Extension Replacement - Front > Page 8624 * Check the height and the alignment to the rocker panel. * Check the height and the alignment to the rocker panel cladding and to the body. If the vehicle is equipped with assist steps, the cladding will be shorter across the bottom. 1. Install the rear section of the assist step extension, align the rear edge of the assist step with the rear edge of the retainer and pushing downward until fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw to the left rear outer edge of the assist step extension. Lift upward on the assist step until fully released from the retainer. Tighten the screw to the left rear outer edge of the assist step extension to 2 N.m (18 lb in). 3. Install the screws to the right rear inner and outer wheel well. Open the sliding door to expose the screw. Lift upward on the assist step extension until fully released from the retainer Tighten the screws to the right rear inner and outer wheel well to 2 N.m (18 lb in). 4. Install the front section of the assist step extension. Refer to Assist Step Plate Replacement (See: Assist Step Plate Replacement) . 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8631 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 3. Remove the front bumper fascia to bumper lower brace bolts. 4. Remove the front bumper fascia to fender bolts. 5. Remove the front bumper fascia to impact bar push-in retainers. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8632 6. Remove the front bumper fascia from the impact bar. Installation Procedure 1. Install the front bumper fascia to the impact bar. 2. Install the front bumper fascia to impact bar push-in retainers. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the front bumper fascia to the fender bolts. Tighten the bolts to 6 N.m (53 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8633 4. Install the front bumper fascia to the bumper lower brace bolts. Tighten the bolts to 6 N.m (53 lb in). 5. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 8638 Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Remove the front bumper fascia. Refer to Fascia Replacement - Front Bumper (See: Front Bumper Cover / Fascia/Service and Repair) . 3. Remove the bracket bolts from the impact bar. 4. Remove the impact bar from the vehicle. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the impact bar to the bracket bolts. Tighten the bolts to 58 N.m (43 lb ft). 2. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper (See: Front Bumper Cover / Fascia/Service and Repair) . 3. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 8644 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper Removal Procedure 1. Remove the top fascia retainers. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 3. Disengage the retainers from the underside of the fascia. 4. Remove the fascia from the impact bar. Installation Procedure 1. Align the locator pin of the fascia to the hole in the impact bar. 2. Press the retainers into the underside of the fascia. 3. Lower the vehicle. 4. Install the top fascia retainers. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL PROCEDURE IMPORTANT: It door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door. 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. INSTALLATION PROCEDURE IMPORTANT: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer. 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 8660 5. Install the nuts to the door handle (4). Tighten Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. 7. Install the access hole plug (1). 8. Install the water deflector. 9. Install the trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Hinge Replacement - Front Door Removal Procedure 1. Remove the door. Refer to Door Replacement - Front (See: Service and Repair) . 2. Remove the sealer from around the edge of the hinge. 3. Scribe the location of the existing hinges on the door and the body pillar (1). 4. Center punch each of the original welds on each hinge base (3). 5. Drill a 3.0 mm (1/8 in) pilot hole completely through each weld at each punch mark. Drill through the hinge base only. Do not drill through the door or the body pillar. 6. Drill a 13.0 mm (1/2 in) hole through the hinge base. Use the 3.0 mm (1/8 in) hole as a pilot. Do not drill through the door or the body pillar. 7. Use a chisel in order to separate any remaining weld attaching the hinge to the door or the body pillar. 8. Remove the hinge from the door or the body pillar. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 8664 1. Install the bolt on replacement hinge (4) to the door or the body pillar within the scribe marks (1) previously made: 1. Use the replacement hinge (4) as a template in order to center punch each bolt hole location. 2. Drill a 13.0 mm (1/2 in) hole through the door or the body pillar at the center punch marks made previously. 3. Dress and prepare the door or the hinge pillar for the replacement hinge. This includes grinding off any remaining welds. 2. Apply a medium-bodied sealer to the hinge surface that mates with the door or the hinge pillar surface. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Use the bolts and the anchor plate supplied with the replacement hinge in order to install the hinge to the door. Tighten the bolts hinge to the door to 27 N.m (20 lb ft). 4. Apply paint to the hinge and the surrounding area. 5. Install the door. 6. Adjust the door to fit properly in the door frame. The 13.0 mm (1/2 in) holes drilled for the replacement will provide for some adjustment. Do not completely shut the door until a visual check of the lock fork bolt to striker alignment is made. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the screws and the armrest cover (YC5). 2. Remove the window regulator handle, if equipped. 3. Pull out on the lock lever escutcheon, starting with the front edge, in order to remove the lock lever escutcheon. 4. Pull out on the top edge of the escutcheon and pivot down in order to clear the tab at the trim panel and remove the upper corner trim if equipped. 5. Remove the caps that cover the screws retaining the assist handle. 6. Remove the screws that retain the handle to the door. 7. Remove the one screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. 10. Remove the door courtesy lamp from the door panel, if equipped. Refer to Courtesy Lamp/Reflector Replacement - Door . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8669 11. Use J 38778 to release the door trim panel retainers. 12. Remove the trim panel from the door. Installation Procedure Important: Replace any trim panel retainers that were damaged during removal. 1. Position the trim panel to the door. 2. Secure the trim panel retainers to the door by pressing into the door until fully seated. 3. Place the window seal portion of the panel over the door frame in order to install the trim panel to the door. 4. Install the door courtesy lamp to the door panel. Refer to Courtesy Lamp/Reflector Replacement - Door . 5. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 6. Install the plate to the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the one screw at the front edge of the accessory switch mount plate. Tighten the one screw at the front edge of the accessory switch mount plate to 2 N.m (18 lb in). 8. Install the handle to the door with screws. Tighten the handle to the door with screws to 5 N.m (44 lb in). 9. Install the caps that cover the screws on the assist handle. 10. Insert the tab in the slot on the door trim panel and seat the fastener into the door at the top in order to install the upper corner trim. 11. Push the lock lever escutcheon into place, starting at the rear edge. 12. Install the window regulator handle, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8670 13. Install the armrest cover and the screws (YC5). Tighten the armrest cover screws to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8671 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door Water Deflector Replacement - Front Door Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: ) . 2. Use a 6 mm (0.24 in) drill bit in order to remove the head from the door bracket rivets. 3. Remove the rivets that retain the bracket to the door. Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 4. In order to remove the water deflector, several components need to be removed first. Remove the armrest bracket. 5. Remove the lock lever. 6. Use a soft-faced scraper in order to peel the water deflector away from the door. Installation Procedure Important: When replacing deflectors which have been peeled back or removed, the adhesive on the door and the deflector from the factory will usually be adequate in order to re-adhere the deflector to the door. If additional adhesive is required, use a small amount of weatherstrip adhesive, such as GM P/N 12345096, Canadian P/N 993365, or an equivalent adhesive. If the deflector was separated at a perforation, use a cloth reinforced tape with a strong adhesive in order to secure the piece together. Replace the deflector if the deflector Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Panel Replacement > Page 8672 is too badly damaged to provide a proper seal. 1. Install the water deflector. 2. Install the lock lever. 3. Install the armrest bracket to the door. 4. Install the 6 mm (1/4 in) rivets to the door. 5. Install the trim panel. Refer to Trim Panel Replacement - Door (See: ) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement Front Door Striker: Service and Repair Door Striker Replacement Striker Replacement - Door Tools Required J 29843-9 Door Lock Striker and Seat Belt Torx Wrench Removal Procedure 1. Remove the interior trim if necessary to gain access to the striker nut. 2. Remove door striker using J 29843-9 . Hold the nut in order to prevent the nut from falling into the body pillar. 3. Remove the nut from the vehicle. 4. Remove the spacer from the vehicle. 5. Remove the insulator from the vehicle. 6. Adjust the striker to properly engage the door lock once the door is adjusted within the frame. 7. Ensure that the striker is used to adjust the door for flushness only, not to raise or lower the door. Installation Procedure 1. Install the spacer and the insulator to the striker. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door striker using J 29843-9 . Hold the nut in order to prevent the nut from falling into the body pillar. Tighten the door striker to 67 N.m (49 lb ft). 3. Install the interior trim which was previously removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement > Page 8677 Front Door Striker: Service and Repair Striker Replacement - Sliding Door Rear Striker Replacement - Sliding Door Rear Removal Procedure 1. Remove the right hand body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 2. Remove the two bolts that retain the rear storage compartment, if equipped. 3. Remove the bolts (5). 4. Remove the striker (4). 5. Remove the spacer (3). 6. Remove the washer (2). 7. Remove the nut plate (1). Installation Procedure 1. Install the nut plate (1). 2. Install the washer (2). 3. Install the spacer (3). 4. Install the striker (4). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the striker bolts (5). Tighten the striker bolts to 24 N.m (18 lb ft). 6. Install the right hand body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the interior garnish moldings. 2. Use the J 38778 in order to pull the weatherstrip from the pinchweld flange of the door. Start at the upper right corner (6), and pull the weatherstrip down (5,4). Keep pulling the weatherstrip (3) until you reach the top (1) of the door, and have pulled the weatherstrip free. Installation Procedure Important: Ensure that the weatherstrip length is equally distributed around the door opening. 1. Partially attach the weatherstrip to the pinchweld flange in 6 key areas (1,2,3,4,5,6). Important: Fit the weatherstrip to the opening by hand. 2. Seat the weatherstrip onto the pinchweld flange to approximately 154 mm (6 in) on each side of the corner in order to install the weatherstrip at each corner (6,4,3,1). Important: Use a rubber mallet and hit the weatherstrip square to the flange. Otherwise, an undesirable spreading of the carrier will occur that will result in reduced retention. 3. Use a rubber mallet in order to install the weatherstrip into each corner. 4. Use a rubber mallet in order to install the pinchweld flange areas of the hinge and the windshield pillars. 5. Ensure that the following conditions are met: * The weatherstrip fits into the corner and matches the radius of the pinchweld flange. * The weatherstrip is seated completely onto the flange in all areas, resulting in a smooth vinyl-trim around the entire door opening. * There is not any distortion or excess spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. * The weatherstrip is not kinked or distorted after installation. * The weatherstrip is lubricated with GM weatherstrip silicone lube. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 8681 * Install the interior garnish moldings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure 1. Remove the power window regulator. Refer to Window Regulator Replacement (See: Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install a self-tapping, pan head sheet metal screw through the sector gear and the backing plate at the hole provided. This will lock the sector gear into position. 3. Drill out the rivets (2) attaching the power window motor to window regulator . 4. Remove the power window motor from the window regulator (3). Installation Procedure 1. Install the power window motor to the window regulator (3). Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install the rivets (2) attaching the power window motor to window regulator . 3. Remove the self-tapping, pan head sheet metal screw through the sector gear and the backing plate hole. 4. Install the power window regulator. Refer to Window Regulator Replacement (See: Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Replacement Door Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Door Trim Panel Replacement (See: Front Door Panel/Service and Repair) . 2. Remove the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement See: Front Door Panel/Service and Repair Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward. and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Front Side Door Water Deflector Replacement See: Front Door Panel/Service and Repair 5. Install the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Door Trim Panel Replacement (See: Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 8693 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door Panel/Service and Repair) . 2. Remove the bolts that retain the inner panel upper bar. 3. Remove the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door Panel/Service and Repair. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 8694 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door Panel/Service and Repair. 5. Install the inner panel upper bar with the bolts. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside Rear Door Exterior Handle: Service and Repair Handle Replacement - Rear Door Outside Handle Replacement - Rear Door Outside Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 3. Remove the control rod from the outside handle. 4. Remove the outside handle nuts. 5. Remove the outside handle. Installation Procedure 1. Install the outside handle to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the outside handle nuts. Tighten the outside handle nuts to 7 N.m (62 lb in). 3. Install the control rod to the outside handle through the clip. 4. Install the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 5. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside > Page 8701 Rear Door Exterior Handle: Service and Repair Door Handle Replacement Outside Handle and Lock Cylinder Replacement Removal Procedure Important: If door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door See: Front Door/Front Door Panel/Service and Repair 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. Installation Procedure Important: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer . 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the nuts to the door handle (4). Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Handle Replacement - Rear Door Outside > Page 8702 7. Install the access hole plug (1). 8. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Front Door/Front Door Panel/Service and Repair 9. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door Removal Procedure 1. Remove the door from the vehicle. Refer to Door Replacement - Rear (Cargo Doors) (See: Service and Repair/Door Replacement - Rear (Cargo Doors))Door Replacement - Rear (E54) (See: Service and Repair/Door Replacement - Rear (E54)) . 2. Remove the taillamp. Refer to Tail Lamp Replacement . 3. Remove the taillamp filler panel. 4. Remove the trim panel: Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 1. Scribe an outline of the hinge halves on the door (2) and the body (1). 2. Use the template provided with the service hinge in order to center punch the existing welds. 3. Drill a 3.0 mm (1/8 in) pilot hole completely through the following components at the punch marks: * Hinge * Frame * Reinforcement * Gusset 4. Use the pilot holes as guides in order to drill a 13.0 mm (1/2 in) hole through the following components at the punch marks: * Hinge * Frame * Reinforcement * Gusset 5. Drive a chisel between the hinge and the door frame if any additional weld holds the hinge to the frame in order to remove the hinge halves. 6. Remove any additional weld on the door or the body side frame. This step may include using a grinder in order to remove any remaining weld. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Page 8706 1. Install the hinge pin bushings. 2. Apply a medium-bodied sealer to the mating surface of the hinge halves. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the following components to the door and the body frame: * Anchor plates * Bolts (3) Tighten the bolts to the door and the body frame to 27 N.m (20 lb ft). * Hinge halves Align the hinge with the previously made mark. 4. Paint the hinge and the surrounding area. 5. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 6. Install the taillamp filler panel. 7. Install the taillamp. Refer to Tail Lamp Replacement . 8. Install the door to the vehicle. Refer to Door Replacement - Rear (Cargo Doors) (See: Service and Repair/Door Replacement - Rear (Cargo Doors))Door Replacement - Rear (E54) (See: Service and Repair/Door Replacement - Rear (E54)) . 9. Adjust the door to fit properly in the door opening frame: 1. Ensure that the left door is closed when adjusting the right door. 2. Do not close the right door completely until a visual check is made in order to determine that the lock assembly is properly engaged to the striker. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) Rear Door Limiter: Service and Repair Check Link Replacement - Rear Door (Cargo Door) Check Link Replacement - Rear Door (Cargo Door) Removal Procedure 1. Open the door. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 3. Remove the water deflector. 4. Remove the check link from the check link mounting bracket by lifting upward to release. Important: Remove the one screw that retains the check link lock spring, if replacing just the check link lock spring. When replacing the check link bracket all three screws will need to be removed. Remove one screw at a time when replacing the check link bracket. If all three screws are removed at once this may cause the loss of the threaded anchor plate. If this occurs, remove the taillamp and the taillamp pocket in order to access the cavity where the threaded plate is located. 5. Remove the check link screws from the bracket (2). 6. Remove the check link bracket (1) and the check link lock spring. 7. Remove the check link bolts from the door. 8. Remove the check link boot from the door (6). 9. Remove the check link (5) from the inside of the door. Installation Procedure 1. Install the check link (5) to the door. 2. Install the check link boot to the door (6). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the check link boot bolts to the door. Tighten the check link bolts to the door to 6 N.m (53 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8711 4. Install the check link bracket (1) and the check link lock spring. 5. Install the check link bracket screws (2). Tighten the check link bracket screws to 4 N.m (35 lb in). 6. Install the water deflector. 7. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8712 Rear Door Limiter: Service and Repair Check Link Replacement - Rear Door (E54) Check Link Replacement - Rear Door (E54) Removal Procedure 1. Open the door. 2. Remove the door trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 3. Remove the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 4. Remove the check link from the check link mounting bracket by lifting upward to release. Important: Remove the one screw that retains the check link lock spring, if replacing just the check link lock spring. When replacing the check link bracket all three screws will need to be removed. Remove one screw at a time when replacing the check link bracket. If all three screws are removed at once this may cause the loss of the threaded anchor plate. If this occurs, remove the taillamp and the taillamp pocket in order to access the cavity where the threaded plate is located. 5. Remove the check link screws from the bracket (2). 6. Remove the check link bracket (1) and the check link lock spring. 7. Remove the check link bolts from the door. 8. Remove the check link boot from the door (6). 9. Remove the check link (5) from the inside of the door. Installation Procedure 1. Install the check link (5) to the door. 2. Install the check link boot to the door (6). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the check link boot bolts to the door. Tighten the check link bolts to the door to 6 N.m (53 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Limiter > System Information > Service and Repair > Check Link Replacement - Rear Door (Cargo Door) > Page 8713 4. Install the check link bracket (1) and the check link lock spring. 5. Install the check link bracket screws (2). Tighten the check link bracket screws to 4 N.m (35 lb in). 6. Remove the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 7. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Rear Door Trim Panel Replacement (Cargo Doors) Rear Door Trim Panel Replacement (Cargo Doors) Removal Procedure 1. Remove the window garnish molding. Refer to Window Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Window Garnish Molding Replacement). 2. Remove the screws. 3. Remove the trim panel. Installation Procedure 1. Install the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the trim panel screws. Tighten the trim panel screws to 2 Nm (18 lb.in.). 3. Install the window garnish molding. Refer to Window Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Window Garnish Molding Replacement). Rear Door Trim Panel Replacement (E54) Rear Door Trim Panel Replacement (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8718 1. Remove the lace. 2. Use J 38778 in order to remove the trim panel. Installation Procedure 1. Install the trim panel to the door. 2. Install the lace. Door Trim Panel - Rear Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8719 TRIM PANEL REPLACEMENT - DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the screws and the armrest cover (YC5). 2. Remove the window regulator handle, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8720 3. Pull out on the lock lever escutcheon, starting with the front edge, in order to remove the lock lever escutcheon. 4. Pull out on the top edge of the escutcheon and pivot down in order to clear the tab at the trim panel and remove the upper corner trim if equipped. 5. Remove the caps that cover the screws retaining the assist handle. 6. Remove the screws that retain the handle to the door. 7. Remove the one screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. 10. Remove the door courtesy lamp from the door panel, if equipped. 11. Use J 38778 to release the door trim panel retainers. 12. Remove the trim panel from the door. INSTALLATION PROCEDURE IMPORTANT: Replace any trim panel retainers that were damaged during removal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8721 1. Position the trim panel to the door. 2. Secure the trim panel retainers to the door by pressing into the door until fully seated. 3. Place the window seal portion of the panel over the door frame in order to install the trim panel to the door. 4. Install the door courtesy lamp to the door panel. 5. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 6. Install the plate to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the one screw at the front edge of the accessory switch mount plate. Tighten Tighten the one screw at the front edge of the accessory switch mount plate to 2 N.m (18 lb in). 8. Install the handle to the door with screws. Tighten Tighten the handle to the door with screws to 5 N.m (44 lb in). 9. Install the caps that cover the screws on the assist handle. 10. Insert the tab in the slot on the door trim panel and seat the fastener into the door at the top in order to install the upper corner trim. 11. Push the lock lever escutcheon into place starting at the rear edge. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8722 12. Install the window regulator handle, if equipped. 13. Install the armrest cover and the screws (YC5). Tighten Tighten the armrest cover screws to 5 N.m (44 lb in). For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and ID/RPO Codes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8723 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Peel the water deflector from the door and remove from the door. Installation Procedure 1. Install the water deflector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8724 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 8725 Rear Door Panel: Service and Repair Access Cover Replacement - Cargo Van Upper Access Cover Replacement - Cargo Van Upper Removal Procedure 1. Remove the screws (3) that retain the upper access cover (2) to the door. 2. Remove the upper access cover (2) from the door. Installation Procedure 1. Install the upper access cover (2) to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws (3) that retain the upper access cover to the door. Tighten the screws that retain the upper access cover to the door to 4 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair Rear Door Striker: Service and Repair Door Striker Replacement - Left Rear Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Separate the water deflector at the perforations. Use a sharp-bladed tool if needed. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 3. Remove the nuts from the striker (2). 4. Remove the insulator (3). 5. Remove the striker (4). Installation Procedure 1. Install the striker to the door (4). The narrow part on the wedge plate of the striker should point toward the rear of the vehicle. 2. Install the insulator (3). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nuts to the striker (2). Tighten the nuts to the striker to 30 N.m (22 lb ft). 4. Install the water deflector. Refer to Water Deflector Replacement (See: Rear Door Panel/Service and Repair) . 5. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Outer Belt Sealing Strip Replacement - Outer Belt Removal Procedure 1. Roll the window down. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 3. Remove the outer sealing strip from the door frame. Installation Procedure 1. Install the outer sealing strip to the door frame. 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8733 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (Cargo Doors) Weatherstrip Replacement - Rear Door (Cargo Doors) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers (2). 2. Use the 3M Release Agent or an equivalent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic weather retainers (3). 4. Remove the weatherstrip (1) from the left door. 5. Remove the weatherstrip from the right door. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip to the right door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8734 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip (3) to the left door. 3. Install the plastic retainers (2) into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8735 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (E54) Weatherstrip Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers. 2. Use 3M Release Agent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic retainers. 4. Remove the left door weatherstrip. 5. Remove the right door weatherstrip. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the right door weatherstrip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 8736 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the left door weatherstrip. 3. Install the plastic retainers into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Center Sliding Door Roller > Component Information > Service and Repair Center Sliding Door Roller: Service and Repair Roller Bracket Replacement - Center Removal Procedure 1. Remove the center roller track cover. Refer to Center Track Cover Replacement - Sliding Door () . 2. Position the sliding door inward for door clearance. Remove the bolts (5) that retain the center roller bracket (2) to the door. 3. Disconnect the retaining spring located around the pin in order to release. 4. Support the sliding door at the bottom rear corner. 5. Slide the bracket rearward. 6. Remove the bracket (2) from the center roller track. Installation Procedure 1. Install the bracket (2) to the center roller track. 2. Slide the bracket forward. 3. Remove the support from the sliding door. 4. Push the retaining pin back in place. 5. Check the retaining spring located around the pin for damage. If damaged, replace the spring. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts (5) that retain the center roller bracket to the door. Tighten the center roller bracket retaining bolts to 35 N.m (26 lb ft). 7. Install the center roller track cover. Refer to Center Track Cover Replacement - Sliding Door () . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair Lower Sliding Door Roller: Service and Repair Roller Bracket Replacement - Lower Removal Procedure 1. Use a grease pencil in order to mark the position of the bracket on the door. 2. Disconnect the lower corner of the door trim panel to expose the bracket (2) to door bolts. 3. Support the bottom of the door. 4. Remove the bracket (2) to door bolts. 5. Slide the bracket (2) out of the rear of the track in order to remove the bracket from the body. Installation Procedure 1. Slide the bracket rollers (2) into the rear of the track in order to install the bracket to the body. 2. Align the bracket with the marks made during removal in order to install the bracket to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts that retain the bracket to the door. Tighten the bracket retaining bolts to 25 N.m (18 lb ft). 4. Remove the support from the bottom of the door. 5. Install the lower corner of the door trim panel by pressing into place until fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair Sliding Door Handle: Service and Repair Door Handle Replacement - Outside Sliding Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . 2. Remove the water deflector. Refer to Water Deflector Replacement - Sliding Door (See: Sliding Door Interior Trim Panel/Service and Repair/Water Deflector Replacement - Sliding Door) . 3. Remove the lock control. Refer to Lock Replacement - Sliding Door (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Lock Replacement - Sliding Door) . 4. Remove the lock rods from the handle (1). 5. Remove the outside handle nuts (2). 6. Remove the outside handle and gasket from the door. Installation Procedure 1. Install the outside handle and gasket to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the outside handle nuts (2). Tighten the outside handle nuts to 6 N.m (50 lb in). 3. Install the lock rods to the handle (1). 4. Install the lock control. Refer to Lock Replacement Sliding Door (See: Locks/Door Locks/Service and Repair/Removal and Replacement/Lock Replacement - Sliding Door) . 5. Install the water deflector. Refer to Water Deflector Replacement - Sliding Door (See: Sliding Door Interior Trim Panel/Service and Repair/Water Deflector Replacement - Sliding Door) . 6. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Sliding Door Interior Trim Panel: Service and Repair Sliding Door TRIM PANEL REPLACEMENT - SLIDING DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the screws that retain the inside handle bezel (1) to the door. 2. Pull in order to disengage the clips (2). 3. Remove the inside handle bezel (1). 4. Remove the garnish molding. 5. Use J 38778 in order to release the trim panel retainers. 6. Remove the sliding door trim panel. INSTALLATION PROCEDURE 1. Install the trim panel to the door: 1.1. Align the retainers to the holes in the door. 1.2. Press the panel in order to engage the retainers into the door. 2. Press in order to engage the clips and install the inside handle bezel. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door > Page 8751 3. Install the screws (3) that retain the inside handle bezel (1). Tighten Tighten the screws that retain the inside handle bezel to 2 N.m (18 lb in). 4. Install the garnish molding. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door > Page 8752 Sliding Door Interior Trim Panel: Service and Repair Sliding Door Trim Panel Replacement Trim Panel Replacement - Sliding Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the screws that retain the inside handle bezel (1) to the door. 2. Pull in order to disengage the clips (2) and remove the inside handle bezel (1). 3. Remove the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. 4. Use J 38778 in order to release the trim panel retainers. 5. Remove the sliding door trim panel. Installation Procedure 1. Install the trim panel to the door: 1. Align the retainers to the holes in the door. 2. Press the panel in order to engage the retainers into the door. 2. Press in order to engage the clips (2) and install the inside handle bezel (1). Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws (3) that retain the inside handle bezel (1). Tighten the screws that retain the inside handle bezel to 2 N.m (18 lb in). 4. Install the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door > Page 8753 Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door > Page 8754 Sliding Door Interior Trim Panel: Service and Repair Water Deflector Replacement - Sliding Door Water Deflector Replacement - Sliding Door Removal Procedure 1. Remove the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. 2. Remove the trim panel. Refer to Trim Panel Replacement - Sliding Door (See: ) . Important: Water deflectors seal the inner panel. Water deflectors prevent water from entering into the body. A strip of adhesive between the deflector and the door secures the deflector. 3. Peel the water deflector (1) away from the door. Installation Procedure Important: When replacing deflectors which have been peeled back or removed, the adhesive on the door and the deflector from the factory will usually be adequate in order to re-adhere the deflector to the door. If additional adhesive is required, use a small amount of weatherstrip adhesive, such as GM P/N 12345096, Canadian P/N 993365, or an equivalent adhesive. If the deflector was separated at a perforation, use a cloth reinforced tape with a strong adhesive in order to secure the piece together. Replace the deflector if the deflector is too badly damaged to provide a proper seal. 1. Install the water deflector (1). Important: Ensure that the water deflector is properly attached to the door in order to help prevent the intrusion of exhaust gases. 2. Install the trim panel. Refer to Trim Panel Replacement - Sliding Door (See: ) . 3. Install the garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) in Interior Trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Upper Sliding Door Roller > Component Information > Service and Repair Upper Sliding Door Roller: Service and Repair Roller Bracket Replacement - Upper Removal Procedure 1. Remove the upper roller bracket garnish molding. 2. Remove the rubber stopper from the upper roller track. 3. Remove the front cap. 4. Remove the bracket (1) to door bolts (4). 5. Remove the upper roller bracket from the track. Installation Procedure 1. Install the upper roller bracket (1) to the track. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bracket to door and bolts (4). Tighten the bracket bolts to the door to 25 N.m (18 lb ft). 3. Install the front cap. 4. Install the rubber stopper to the upper roller track. 5. Install the upper roller bracket garnish molding. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Striker > Component Information > Service and Repair Sliding Door Striker: Service and Repair Striker Bolt Replacement - Sliding Door Front Removal Procedure 1. Remove the shoulder belt guide bolt from the door pillar. Refer to Seat Belt Retractor Replacement - Right Rear . 2. Pull the trim panel forward and reach behind the trim panel to the striker bolt nut in order to remove the screw at the bottom of the door pillar trim. 3. Remove the striker bolt (4). 4. Remove the striker nut (1). Installation Procedure 1. Install the striker nut to the inside of the door pillar. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the striker bolt (4). Tighten the striker bolt to 67 N.m (49 lb ft). 3. Install the trim panel to the door pillar and the screw. 4. Install the shoulder belt guide bolt to the door pillar. Refer to Seat Belt Retractor Replacement - Right Rear . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement Fuel Door: Service and Repair Fuel Filler Door Replacement Fuel Filler Door Replacement Removal Procedure 1. Remove the screws that retain the fuel filler door. 2. Remove the fuel filler door. Installation Procedure 1. Install the fuel filler door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the fuel filler door. Tighten the screws that retain the fuel filler door to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement > Page 8765 Fuel Door: Service and Repair Fuel Filler Pocket Replacement Fuel Filler Pocket Replacement Removal Procedure 1. Remove the fuel filler door. Refer to Fuel Filler Door Replacement (See: Fuel Filler Door Replacement) . 2. Remove the fuel filler cap. 3. Remove the screws that retain the pocket to the fuel filler pipe. 4. Remove the screws that retain the fuel filler pocket to the body. 5. Remove the fuel filler pocket. Installation Procedure 1. Install the fuel filler pocket. 2. Install the screws that retain the fuel filler pocket to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the pocket to the fuel filler pipe. Tighten the screws that retain the pocket to the fuel filler pipe to 2 N.m (18 lb in). 4. Install the fuel filler cap. 5. Install the fuel filler door. Refer to Fuel Filler Door Replacement (See: Fuel Filler Door Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure 1. Remove the air inlet panel grille. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair) . Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 2. Raise and support the hood. 3. Remove the hinge to fender nut. 4. Remove the hinge to fender bolt. 5. Using a grease pencil, mark the position of the hinge to hood. 6. Remove the hinge to hood bolts. 7. Remove the hinge from the hood. Installation Procedure 1. Install the hinge to the hood with the aid of an assistant. 2. Align the new hinge according to the marks made before the old hinge was removed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 8770 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the hood to hinge bolts. Tighten the bolts to 25 N.m (18 lb ft). 4. Install the hinge to fender nut. 5. Install the hinge to fender bolt. Tighten the bolt to 25 N.m (18 lb ft). 6. Lower the hood. 7. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Cowl/Cowl Moulding / Trim/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Raise the hood. 2. Remove the hood insulator push-in retainers by using J 38778 . 3. Remove the insulator from the hood. Installation Procedure 1. Install the hood insulator to the hood. 2. Install the hood insulator retainers into the hood by pushing in the retainers. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary Hood Latch: Service and Repair Hood Latch Replacement - Primary Hood Latch Replacement - Primary Removal Procedure 1. Remove the hood release cable from the latch with the following procedure: 1. Place a screwdriver into the cable clip. 2. Pry the cable clip open in order to remove the cable. 3. Pry the cable housing from the latch. 2. Remove the primary latch support bolts to the radiator. 3. Remove the primary latch with the bracket from the vehicle. 4. Remove the bracket from the latch. Installation Procedure 1. Install the bracket to the latch. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the primary latch to the bracket bolts. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the primary latch and bracket to the vehicle. Important: In the next step, do not tighten the bolts. 4. Install the primary latch support bolts to the radiator. 5. Adjust the latch right and left until the latch lines up with the striker pins in the hood. 6. Raise the hood and tighten the latch to the radiator support bolts. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8778 7. Use a suitable tool in order to crimp the cable clip and retain the hood release cable to the latch. 8. Verify that the hood is operating correctly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8779 Hood Latch: Service and Repair Hood Latch Replacement - Secondary Hood Latch Replacement - Secondary Removal Procedure 1. Remove the hood latch bolt. 2. Remove the secondary hood latch from the hood. Installation Procedure 1. Install the secondary hood latch to the hood. Position the tab into the slot. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hood latch bolt Tighten the hood latch bolt to 27 N.m (20 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement - Primary > Page 8780 Hood Latch: Service and Repair Hood Pop-Up Spring Replacement Hood Pop-Up Spring Replacement Removal Procedure Using a suitable flat-bladed tool, push on the hood mounted end of the spring outward to remove the spring from the hood. Installation Procedure Insert the spring into the hood retainers in order to install the spring to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair HOOD RELEASE LEVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left cowl side trim panel 2. Remove the screws that retain the hood release lever to the cowl side trim panel. 3. Remove the hood release cable from the hood latch. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Page 8784 1. Install the hood release cable to the hood latch. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws that retain the hood release lever to the cowl side trim panel. Tighten Tighten the hood release lever screws to 8 N.m (71 lb in). 3. Install the left cowl side trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Latch Release Cable Replacement Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Hood Latch Release Cable Replacement Removal Procedure 1. Disconnect the cable from the primary latch with the following procedure: 1. Use a suitable tool to pry the cable clip open to allow removal of the cable. 2. Pry the cable housing from the latch. 2. Remove the cable from the fasteners on the radiator support. 3. Remove the cable grommet from the cowl by gently pulling on the grommet. 4. Disconnect the cable from the cowl. 5. Remove the left cowl side trim panel. Refer to Trim Panel Replacement Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . 6. Pull the cable through the cowl in order to remove the screws that retain the cable assembly to the cowl side panel. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Latch Release Cable Replacement > Page 8789 1. Route the cable through the front of the cowl. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the cable to cowl side panel. Tighten the screws to 2 N.m (18 lb in). 3. Install the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . 4. Pull the cable assembly from the front of the cowl until the grommet is seated. 5. Connect the cable to the fasteners in the radiator support. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Latch Release Cable Replacement > Page 8790 6. Use a suitable tool in order to clamp the cable clip and connect the cable to the primary latch. 7. Verify that the hood is operating correctly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Latch Release Cable Replacement > Page 8791 Hood Latch Release Cable: Service and Repair Hood Release Lever Replacement Hood Release Lever Replacement Removal Procedure 1. Remove the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . 2. Remove the screws that retain the hood release lever to the cowl side trim panel. 3. Remove the hood release cable from the hood latch. Refer to Hood Latch Release Cable Replacement (See: Hood Latch Release Cable Replacement) in Body Front End. Installation Procedure 1. Install the hood release cable to the hood latch. Refer to Hood Latch Release Cable Replacement (See: Hood Latch Release Cable Replacement) in Body Front End. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Latch Release Cable Replacement > Page 8792 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the hood release lever to the cowl side trim panel. Tighten the hood release lever screws to 8 N.m (71 lb in). 3. Install the left cowl side trim panel. Refer to Trim Panel Replacement - Cowl Side (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Panel Replacement - Cowl Side) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open Rod Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Raise and suitably support the hood without using the support rod. 2. Remove the support rod-to-radiator support bolt. 3. Remove the support rod from the vehicle. 4. Use a suitable tool to carefully pry the support rod retainer from the vehicle. Installation Procedure 1. Push the support rod retainer into place. 2. Insert the retainer tab into the slot in order to install the support rod to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the support rod-to-radiator support bolt. Tighten the support rod to radiator support bolts to 15 N.m (11 lb ft). 4. Lower the hood. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Measure the height of the hood adjust front bumper before removing in order to aid in adjustment. 2. Rotate the hood adjust front bumper counterclockwise. Installation Procedure 1. Rotate the hood adjust front bumpers clockwise until the hood adjust front bumper is at the same height as measured before removal. 2. Check the alignment of the hood panel assembly. Ensure the top of the hood is flush with the fenders and parallel to the grille. 3. Rotate the bumper clockwise or counterclockwise in order to align the hood. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the rear hood seal retainers by using J 38778 . 2. Remove the rear hood seal from the hood. Installation Procedure 1. Install the rear hood seal to the hood. 2. Push the retainers into the hood in order to retain the rear hood seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Window Replacement - Lift Gate Tools Required * J 24402-A Glass Sealant (Cold Knife) Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Disconnect the washer hose from the liftgate. 2. Remove the back window wiper arm from the liftgate. Refer to Wiper Arm Replacement - Rear in Wipers/Washer Systems. 3. Open liftgate window. 4. Remove the liftgate window garnish molding. Refer to Garnish Molding Replacement Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) in Body Rear End. 5. Disconnect the electrical connector from the rear window defogger on the liftgate window. Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 6. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting 7. Using a sharp utility knife, make a preliminary cut around the perimeter of the quarter window. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8806 Important: Keep the cutting edge of the tool against the window. 8. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the window. 9. With the aid of an assistant, remove the liftgate window from the liftgate frame. Installation Procedure 1. Install a stationary window into the opening. Refer to Urethane Adhesive Installation of Stationary Windows (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Urethane Adhesive Installation of Stationary Windows) . 2. Connect the electrical connector to the rear window defogger on the liftgate window. 3. Install the liftgate window garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) in Body Rear End. 4. Close liftgate window. 5. Install the back window wiper arm to the liftgate. Refer toWiper Arm Replacement - Rear in Wipers/Washer Systems. 6. Connect the washer hose to the liftgate. 7. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair Power Trunk / Liftgate Lock Actuator: Service and Repair Lock Actuator Replacement - Lift Gate Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the brace from the liftgate. 3. Remove the wiper motor from the liftgate. 4. Remove the actuator electrical connector. 5. Remove the right and the left control rods from the actuator lever. 6. Use a 5 mm (3/16 in) drill bit in order to drill out the head of the rivet. 7. Remove the actuator from the liftgate rivets. 8. Remove the actuator from the liftgate. Installation Procedure 1. Install the actuator to the liftgate. 2. Use M 39010 in order to install the actuator to the liftgate rivets. Important: Install new retainers whenever the control rods are removed. 3. Install the right and the left control rods to the actuator lever. 4. Install the wiper motor to the liftgate. 5. Install the actuator electrical connector. 6. Install the brace to the liftgate. 7. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lift Gate Latch Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding (1). Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the control rods from the actuator lever (2). 3. Remove the liftgate latch screws (6). 4. Remove the slide latch (4) from the liftgate. 5. Remove the control rod from the liftgate. 6. Remove the control rod from the liftgate latch. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8814 1. Install the latch (4) with the control rod to the liftgate (3). Notice: Refer to Fastener Notice in Cautions and Notices. Important: Install the new retainers whenever the control rods are removed. 2. Install the liftgate latch screws (6). Tighten the liftgate latch screws to 10 N.m (88 lb in). 3. Use the following procedure in order to install the control rods to the actuator lever (2): 1. Push the actuator lever and the control rod together (2). 2. Push the control rod through the hole. 4. Install the liftgate garnish molding (1). Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8815 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Lower Latch Replacement - Lower Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Separate the weatherstrip deflector at the perforation. Use a sharp-bladed tool if needed. Refer to Water Deflector Replacement (See: Doors/Rear Door/Rear Door Panel/Service and Repair) . 3. Remove the control rod from the lock assembly. 4. Remove the bolts and the reinforcement. 5. Remove the following components from the door: * The latch * The rod * The retainer 6. Remove the rod and the retainer from the latch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8816 Installation Procedure 1. Install the control rod and the retainer to the latch. 2. Install the retainer as shown in order to prevent squeaks and rattles. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the following components to the door. Ensure that the arrow on the retainer points toward the front of the vehicle: * The latch * The retainer * The bolts Tighten the bolts to the door to 8 N.m (71 lb in). Important: Install new nylon retainers whenever you remove the control rods. 4. Install the control rod to the lock assembly. 5. Install the water deflector. Refer to Water Deflector Replacement (See: Doors/Rear Door/Rear Door Panel/Service and Repair) . 6. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8817 Trunk / Liftgate Latch: Service and Repair Latch Replacement - Upper and Lower Latch Replacement - Upper and Lower Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Peel the water deflector away from the door. Use a soft-surfaced scraper if needed. Refer to Water Deflector Replacement (See: Doors/Rear Door/Rear Door Panel/Service and Repair) . 3. Remove the control rods from the remote lock. 1. Pry the anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod and the clip away from the lever. 4. Remove the upper latch screws. 5. Remove the upper latch, if equipped. 6. Remove the upper latch and the rod from the door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8818 7. Remove the lower latch screws. 8. Remove the reinforcement. 9. Remove the lower latch and the rod from the door. Installation Procedure 1. Install the clips to the remote lock. 2. Install the lower latch and the rod to the door. 3. Install the reinforcement. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch Replacement - Lift Gate > Page 8819 4. Install the lower latch screws. Tighten the lower latch screws to 8 N.m (71 lb in). 5. Install the upper latch and the rod to the door. 6. Install the cover, if equipped. 7. Install the upper latch screws. Tighten the upper latch screws to 10 N.m (88 lb in). 8. Install the control rods through the clips to the remote lock. 9. Install the water deflector. Refer to Water Deflector Replacement (See: Doors/Rear Door/Rear Door Panel/Service and Repair) . 10. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Testing and Inspection Trunk / Liftgate Lock Cylinder: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Trunk/Liftgate, Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Testing and Inspection > Page 8823 Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Disconnect the electrical connector. 3. Remove the rear wiper motor from the liftgate. 4. Remove the lock cylinder retainer. 5. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the lock cylinder retainer. 3. Install the rear wiper motor to the liftgate. 4. Connect the electrical connector. 5. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate Trunk / Liftgate Shock / Support: Service and Repair Strut Ball Stud Replacement - Lift Gate Strut Ball Stud Replacement - Lift Gate Removal Procedure 1. Open and support the liftgate. 2. Remove the strut. Refer to Strut Replacement - Lift Gate (See: Strut Replacement - Liftgate) . 3. Remove the strut ball from the lid or body by turning counterclockwise. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the strut ball to lid or body by turning clockwise into the weldnut. Tighten the strut ball to 25 N.m (18 lb ft). 2. Install the strut. Refer to Strut Replacement - Lift Gate (See: Strut Replacement - Liftgate) . 3. Install the support. Close liftgate. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate > Page 8828 Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Liftgate Strut Replacement - Lift Gate Removal Procedure Caution: When a lift window hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. Notice: Apply pressure only at the end of the hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 1. Open and support the liftgate. 2. Remove the strut retaining clips from each end of the strut. Use a small flat bladed tool to lift up on the retaining clip in order to release the strut from the strut ball. 3. If equipped with a rear window defogger, remove the following components: 1. The body side rear garnish molding from the headliner Refer toTrim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) in Interior Trim. 2. The body side rear garnish molding and speaker as one Refer toTrim Replacement - Third Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Third Pillar Left) in Interior Trim. 3. The rear window defogger electrical connector from the harness 4. The grommet and electrical connector from the body, by pulling the components out 4. Remove the strut. Installation Procedure 1. Install the strut with the following steps: 1. Install the strut to each end of the strut balls. 2. Pull back on the ends of strut to ensure a firm lock. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Strut Ball Stud Replacement - Lift Gate > Page 8829 2. If equipped with a rear defogger, install the following components: 1. The rear window defogger electrical connector to the harness 2. The grommet, fully to the body, in order to ensure that water can not enter 3. The body-side rear garnish molding and speaker as one unit Refer to Trim Replacement - Third Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Third Pillar Left) in Interior Trim. 4. The body-side rear garnish molding to the headliner Refer to Trim Replacement - Fourth Pillar Left (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Trim Replacement - Fourth Pillar Left) in Interior Trim. 3. Inspect the rear defogger operations. 4. Remove the prop and close the liftgate. 5. Inspect the rear defogger in order to verify that the component is operating correctly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Lift Gate Removal Procedure 1. Remove the screws (1). 2. Remove the striker assembly (2). Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. Install the liftgate striker (2) with the screws (1). Tighten the liftgate striker screws to 10 N.m (88 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Remove all of the interior trim in order to access the weatherstrip. 2. Pull the weatherstrip from the pinch-weld flange. Start at the upper right corner. Installation Procedure Important: The weatherstrip attaches to the pinch-weld flange in 6 areas. The weatherstrip length distributes equally around the door opening. 1. Install the weatherstrip at the top right corner. Seat the weatherstrip onto the pinch-weld flange. 2. Position and install the weatherstrip by hand. 3. Using a rubber mallet during the final installation may be required in the thick flange areas and in each corner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Molding/Nameplate Replacement - Exterior Trim Body Emblem: Service and Repair Molding/Nameplate Replacement - Exterior Trim Molding/Nameplate Replacement - Exterior Trim Tools Required J 41409 Body Molding Removal Tool Removal Procedure Remove the emblem or the molding: 1. Apply masking tape to the body side border of the emblem or the molding in order to protect the body from scratches. The tape will also aid in aligning the moldings during installation. 2. Use J 41409 or a 0.8 mm (0.03 in) fishing line in order to cut through the adhesive material. Installation Procedure Important: Apply these items in an environment free of dust or dirt that could come in contact with the sticky backing and prevent proper adhesion. 1. Clean the area where the molding or the emblem is to be mounted. Use a suitable solvent, such as a mixture of 50 percent isopropyl alcohol and 50 percent water, or equivalent. 2. Dry the area thoroughly. 3. Ensure that the body area is at a temperature range of 27-41°C (80-105°F). Heat the area, if needed. 4. Ensure that the emblems are at a temperature range of 29-32°C (85-90°F). Place the emblem, adhesive side down, on a heated surface or use a heat lamp or a heat gun in order to raise the temperature. 5. Remove the protective liner on the back of the molding or the emblem. 6. Apply the molding or the emblem to the body surface. 7. Apply an equal amount of pressure along the molding or the emblem in order to uniformly bond the molding or the emblem to the body surface. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Molding/Nameplate Replacement - Exterior Trim > Page 8843 Body Emblem: Service and Repair Door Lower Molding Replacement (Rear Door) Emblem Replacement - Grille Removal Procedure 1. Remove the grille from the vehicle. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) . 2. Protect the face of the grille while removing the grille emblem. 3. Remove the nuts from the back side of the grille emblem. 4. Remove the grille emblem from the grille. Installation Procedure 1. Install the grille emblem to the grille. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts to the back side of the grille emblem. Tighten the emblem nuts to the grille to 2.5 N.m (22 lb in). 3. Install the grille to the vehicle. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Service and Repair License Plate Bracket: Service and Repair License Plate Pocket Replacement Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 3. Remove the lamp harness from the license plate housing (2). 4. Remove the bolts (1) from the housing. 5. Remove the housing from the door (2). Installation Procedure 1. Install the housing (2) to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the housing to door bolts (1). Tighten the door bolts to 4 N.m (35 lb in). 3. Install the lamp harness to the housing. 4. Install the water deflector. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 5. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Adhesive Retained Cladding Replacement - Adhesive Retained Tools Required * J 41409 Body Molding Removal Tool * 3M 07502 3M Scotch Brite Adhesive Stripe and Removal Disc, or equivalent Attach body cladding to the body with a varying combination of the following items: * Double-sided adhesive tape (1) * Plastic retainers (4) * Screws (2) In order to ensure a good replacement of new or old adhesive retained cladding, ensure that the panel surface temperature is approximately 24-41°C (80-105°F), and the panel surface is clean and free of any wax or oily film. If you will be painting the cladding, do not bake the cladding. Doing this will distort the part, making it useless. Ensure that the replacement screws on the rear side door have a head no taller than the original screws. If screws with a taller head are used, they can cause damage to the body due to physical interference when the door is opened. General procedures are listed below in order to remove adhesive retained to the cladding, and in order to replace the adhesive retained to the cladding. Refer to Cladding Replacement specific component replacement procedures. Removal Procedure 1. Apply masking tape to the body side border of the cladding in order to protect the body from scratches. The tape will also aid in aligning the cladding during installation. 2. Remove all of the mechanical fasteners. Refer to the Cladding Replacement procedure below that is specific to the cladding location. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8854 3. Use the J 41409 or a 0.8 mm (0.03 in) fishing line in order to cut through the adhesive material. Installation Procedure 1. Use a general purpose adhesive remover or an adhesive removal disc (3M 07502 or equivalent) attached to a drill in order to remove all traces of adhesive from the body panel. A 2-3 inch square rubber or felt block may also be used in order to aid in the removal of old adhesive. 2. Clean the affected panel area with wax and grease remover, and wipe with isopropyl alcohol. 3. Mark the proper position of the cladding with masking tape. Use the adjacent cladding as a guide. 4. Warm the body panel with a heat gun or a heat lamp to 24-41°C (80-105°F). 5. Make a trial fitting of the piece to the vehicle, checking the alignment and all the gaps and the clearances. Do this before you remove the plastic backing. Important: Do not distort the part while you are installing the part. The part may take a temporary set to the distorted shape and appear to have the proper adhesion, but the part will spring back to its original shape and cause a loss of adhesion. 6. Once you are satisfied with the trial fit, peel the backing from all of the tape. Set the top row of tape first, and work down the panel to the other rows of tape. Important: Once the cladding is set into place, do not attempt to remove the panel. This will destroy the adhesive strips and could lead to part distortion and damage. 7. Hand roll the cladding to the body in order to ensure proper adhesion. A shop towel rolled into a ball and held in the palm of your fist will aid in applying a consistent, evenly distributed pressure to the panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8855 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Left Quarter Panel Cladding Replacement - Left Quarter Panel Removal Procedure 1. Remove the wheel opening screws. If the vehicle is equipped with assist steps, the cladding will be shorter across the bottom. 2. Remove the cladding from the rear quarter panel. Refer toCladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Installation Procedure 1. Install the cladding to the rear quarter panel. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the wheel opening screws. Tighten the wheel opening screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8856 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Right Quarter Panel Cladding Replacement - Right Quarter Panel Removal Procedure 1. Remove the rear corner extension molding retainers. 2. Remove the rear corner extension molding. 3. Remove the cladding screws. 4. Remove the cladding retainers. 5. Remove the cladding from the body. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Installation Procedure 1. Install the cladding to the body. Refer to Cladding Replacement - Adhesive Retained (See: Cladding Replacement - Adhesive Retained) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the cladding screws. Tighten the cladding screws to 2 N.m (18 lb in). 3. Install the cladding retainers. 4. Install the rear corner extension molding. 5. Install the rear corner extension molding retainers. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8857 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Left Rocker Panel Cladding Replacement - Left Rocker Panel Removal Procedure 1. Remove the screws from the cladding. 2. Remove the retainers from the wheelhouse. 3. Remove the nut on the back of the cladding from the stud. 4. Remove the cladding from the retaining rail. 5. Remove the retaining rail screws. 6. Remove the retaining rail from the body. Installation Procedure 1. Install the retaining rail to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the retaining rail screws. Tighten the retaining rail screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8858 3. Install the cladding to the vehicle. 4. Install the nut on the back of the cladding to the stud. Tighten the nut to 7 N.m (62 lb in). 5. Install the screws into the cladding. Tighten the screws to 2 N.m (18 lb in). 6. Install the retainers into the wheelhouse extension flange. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8859 Upper Side Moulding / Trim: Service and Repair Cladding Replacement - Right Rocker Panel Cladding Replacement - Right Rocker Panel Removal Procedure 1. Remove the screws retaining the front half of the cladding to the front wheelhouse. 2. Remove the push-in retainers from the front wheelhouse. 3. Remove the nut from the stud on the front half of the cladding. 4. Remove the push-in retainers that retain the front half of the cladding to the retaining rail. 5. Remove the cladding from the retaining rail. 6. Remove the screws retaining the rear half of the cladding to the rear wheelhouse. 7. Remove the push-in retainers that retain the rear half of the cladding to the retaining rail. 8. Remove the retaining rail screws. 9. Remove the retaining rail from the body. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Cladding Replacement - Adhesive Retained > Page 8860 1. Install the retaining rail to the body. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the retaining rail screws. Tighten the retaining rail screws to 2 N.m (18 lb in). 3. Install the rear half of the cladding to the retaining rail. 4. Install the push-in retainers that retain the cladding to the retaining rail. 5. Install the screws that retain the cladding to the rear wheelhouse. Tighten the screws to 2 N.m (18 lb in). 6. Install the front half of the cladding to the retaining rail. 7. Install the push-in retainers that retain the front half of the cladding to the retaining rail. 8. Install the nut on the back of the cladding to the stud. Tighten the nut to 7 N.m (62 lb in). 9. Install the retainers into the front wheelhouse extension flange. 10. Install the screws retaining the front half of the cladding to the front wheelhouse. Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Splash Shield Replacement - Wheelhouse Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use J 38778 to remove the retainers from the wheelhouse and the splash shield. 2. Remove the wheelhouse splash shield from the wheelhouse. Installation Procedure 1. Install the wheelhouse splash shield to the wheelhouse. 2. Push the retainers into the wheelhouse holes in order to retain the splash shield to the wheelhouse. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Extension Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use J 38778 in order to remove the retainers from the fender and the extension and from the wheelhouse. 2. Remove the extension from the wheelhouse. Installation Procedure 1. Install the extension to the wheelhouse. 2. Install the extension push pins to the wheelhouse. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement Tools Required J 41602 Body Protection Hoist Adapter Set Removal Procedure 1. Raise the vehicle at the frame. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. Important: Properly support the frame and the body while changing the mount. If you are changing only one mount, the entire side on which the mount is placed must be lowered enough to provide clearance for the mount. 2. Use the J 41602 in order to support the body at the pinchweld flange. 3. Remove the bolts that retain the front bumper fascia at the brace. 4. Remove the bolts that retain the front bumper fascia at the fender. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Page 8874 5. Remove the bolt, the retainer, and the lower insulator of the mount: 1. Loosen the remaining bolts on that side far enough for the upper insulator to be removed. 2. Gradually lower the screw jack in order to allow the frame to come away from the body. 6. Remove the upper body insulator. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the upper body insulator: 1. Gradually raise the screw jack in order to allow the frame to meet the body. 2. Tighten the bolts of the mounts not replaced. Tighten the bolts of the mounts to 35 N.m (26 lb ft). 2. Install the lower insulator, the retainer, and the bolt to the mount. Do not tighten. Important: Follow the body mount tightening sequence. 3. Snug the right #2 body mount (2). 4. Snug the left #2 body mount (2). 5. Tighten the remaining body mounts: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Page 8875 * Tighten the center mount bolt to 155 N.m (114 lb ft). * Tighten the end mount bolts to 90 N.m (66 lb ft). 6. Reinstall the bumper fascia bolts. Tighten the bumper fascia bolts to 6 N.m (53 lb in). 7. Remove the screw jack. 8. Lower the vehicle. 9. Remove the J 41602 from the pinchweld flange. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody Cross-Member: Service and Repair Frame and Underbody Crossmember Brace Replacement - Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the bolts that retain the forward edge of the crossmember brace to the frame. 3. Remove the bolts and the nuts that retain the rear edge of the crossmember brace to the frame. 4. Remove the crossmember brace from the frame. Installation Procedure 1. Install the crossmember brace to the frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts and the nuts in order to retain the rear edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts and the nuts to 35 N.m (26 lb ft). 3. Install the bolts that retain the forward edge of the crossmember brace to the frame. Tighten the crossmember brace to the frame bolts to 35 N.m (26 lb ft). 4. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8880 Cross-Member: Service and Repair Frame Stop Replacement Frame Stop Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the bolts that retain the frame stop to the frame. 3. Remove the frame stop. Installation Procedure 1. Install the frame stop. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the frame stop to the frame. Tighten the bolts that retain the frame stop to 35 N.m (26 lb ft). 3. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8881 Cross-Member: Service and Repair Transmission Support Replacement Transmission Support Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Support the transmission with a transmission jack. 3. Remove the two nuts securing the transmission mount to the transmission support. 4. Remove the transmission support nuts and bolts. 5. Remove the transmission support from the vehicle. Installation Procedure 1. Install the transmission support to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the transmission support nuts and bolts. Tighten the nuts and bolts to 70 N.m (52 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Frame and Underbody > Page 8882 3. Install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to 40 N.m (30 lb ft). 4. Remove the transmission jack. 5. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the hitch from the frame nuts. 3. Remove the hitch to frame bolts. 4. Remove the hitch and bumper from the vehicle. 5. Remove the hitch to bumper nuts. 6. Remove the hitch to bumper bolts. 7. Remove the hitch from the bumper. Installation Procedure 1. Install the hitch to the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hitch to bumper bolts. Tighten the hitch to bumper bolts to 35 N.m (26 lb ft). 3. Install the hitch to bumper nuts. Tighten the hitch to bumper nuts to 25 N.m (18 lb ft). 4. Install the hitch and the bumper to the vehicle. 5. Install the hitch to frame nuts. Tighten the hitch to frame nuts to 60 N.m (44 lb ft). 6. Install the hitch to frame bolts. Tighten the hitch to frame bolts to 55 N.m (41 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8886 7. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Molding Replacement - Lower Grille: Service and Repair Grille Molding Replacement - Lower Grille Molding Replacement - Lower Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille Replacement) . 2. Remove the push-in fasteners that retain the grille molding. 3. Remove the grille molding from the vehicle. Installation Procedure 1. Install the grille molding to the vehicle. 2. Install the push-in fasteners that retain the grille molding. 3. Install the grille. Refer to Grille Replacement (See: Grille Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Molding Replacement - Lower > Page 8891 Grille: Service and Repair Grille Replacement Grille Replacement Removal Procedure 1. Remove the park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement . 2. Remove the screws from the grille to radiator support. 3. Remove the screw from the signal housing. 4. Remove the grille from the vehicle. Installation Procedure 1. Install the grille to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws to grille to radiator support. Tighten the screws to the grille to radiator support to 3 N.m (27 lb in). 3. Install the park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement in Lighting Systems. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) Arm Rest: Service and Repair Armrest Replacement (YC6) Armrest Replacement (YC6) Removal Procedure 1. Remove the armrest by rotating it to the down position. Slip a pair of snap-ring pliers between the seat and the armrest. 2. Ensure that the snap-ring pliers go between the arms of the snap plate. 3. Keeping the armrest plate arms open, pull the armrest straight back off the seat post. Installation Procedure 1. Install the armrest by setting it at approximately 45 degrees. 2. Press the armrest until fully engaged into the groove of the seat post (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8897 Arm Rest: Service and Repair Armrest Replacement (YC7) Armrest Replacement (YC7) Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Place the seat in the fully upright position. 3. Release the J-hook at the bottom of the seat back. 4. Reach up and inside the seat back. Remove the armrest retaining clip. 5. Slide the armrest assembly out of the seat back. 6. Remove the armrest cover for cleaning or replacement: 1. Unzip the armrest cover. 2. Pull the armrest cover off of the seat pad. Installation Procedure 1. Install the armrest cover to the armrest, if the cover was removed. 2. Reach inside the seat back and insert the armrest retaining clip into the seat back frame. * Install the retaining clip with the opening facing down. * Observe the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8898 3. Insert the armrest into the seat back until the armrest retaining clip engages the groove on the armrest post. Pull on the armrest in order to verify that the clip is holding. 4. Attach the halves of the J-hook along the bottom edge of the seat back. 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8899 Arm Rest: Service and Repair Armrest Replacement - Rear Seat (YC7) Armrest Replacement - Rear Seat (YC7) Removal Procedure 1. Place the seat back in the fully-upright position. 2. Release the J-hook along the bottom edge of the seat back. 3. Reach up inside the seat back. Remove the armrest retaining clip. 4. Slide the armrest assembly out of the seat back. 5. Remove the armrest cover for cleaning or replacement, if needed: 1. Unzip the cover. 2. Slide the cover off the armrest. Installation Procedure 1. Install the armrest cover to the armrest, if you removed the cover. 2. Reach inside the seat back. Install the armrest retaining clip: * Install the clip with the opening facing down. * Check the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. 3. Insert the armrest into the seat back until the clip engages the groove on the armrest post. 4. Pull on the armrest in order to verify that the clip is holding the armrest securely. 5. Attach the halves of the J-hook along the bottom edge of the seat back. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8900 Arm Rest: Service and Repair Armrest Replacement - Rear Seat (YC5 and YC6) Armrest Replacement - Rear Seat (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer toSeat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) . 2. Fold down the seat back. 3. Remove the upper and lower seat back latch and seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Left (See: Seats/Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Left) , or Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seats/Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Right (YC6)) . 4. Unzip the seat back cover. 5. Reach inside the seat back and remove the armrest retaining clip from the stud. 6. Remove the armrest from the seat back. 7. Remove the armrest cover for cleaning or replacement, if needed: 1. Unzip the cover. 2. Slide the cover off the armrest. Installation Procedure 1. Install the armrest cover to the armrest, if you removed the cover. 2. Install the armrest from the seat back. 3. Reach inside the seat back and install the armrest retaining clip. * Install the clip with the opening facing down. * Observe the fit of the clip once installed. If the clip is loose when fitted in the groove in the seat back frame, remove the clip and crimp the clip closed slightly. Repeat this procedure until the clip fits snugly in the groove, or install a new clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Replacement (YC6) > Page 8901 4. Zip the seat back cover. 5. Install the upper and lower seat back latch and seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Left (See: Seats/Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Left) , or Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seats/Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Right (YC6)) . 6. Fold up the seat back. 7. Install the rear bench seat to the Vehicle. Refer toSeat Replacement Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8906 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8907 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8908 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 8909 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement Carpet: Service and Repair Carpet Retainer Replacement Carpet Retainer Replacement Removal Procedure 1. Open the door(s). 2. Remove the screws that retain the left front door step trim plate to the vehicle. 3. Remove the screws that retain the right front door step trim plate to the vehicle. 4. Remove the screws that retain the sliding door step trim plate to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8912 5. Remove the screws that retain the rear trim plate to the vehicle. 6. Remove the trim plate from the vehicle. Installation Procedure 1. Install the trim plate to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the left front door step trim plate to the vehicle. Tighten the screws that retain the left front door step trim plate to 2 N.m (18 lb in). 3. Install the screws that retain the right front door step trim plate. Tighten the screws that retain the right front door step trim plate to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8913 4. Install the screws that retain the sliding door step trim plate to the vehicle. Tighten the screws that retain the sliding door step trim plate to 2 N.m (18 lb in). 5. Install the screws that retain the rear trim plate to the vehicle. Tighten the screws that retain the rear trim plate to 2 N.m (18 lb in). 6. Close the door(s). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8914 Carpet: Service and Repair Mat Replacement - Stepwell Mat Replacement - Stepwell Removal Procedure 1. Remove the screws from the step plate cover. 2. Remove the step panel cover. Installation Procedure 1. Install the step panel cover. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8915 Carpet: Service and Repair Mat/Carpet Replacement - Front Floor Mat/Carpet Replacement - Front Floor Removal Procedure 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Remove the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 9. Remove the carpet/mat from the vehicle. Installation Procedure 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. Tighten the screws to the center floor air duct to 2 N.m (18 lb in). 4. Install the front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8916 Replacement) . 8. Install the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8917 Carpet: Service and Repair Mat/Carpet Replacement - Rear Floor (B31) Mat/Carpet Replacement - Rear Floor (B31) Removal Procedure 1. Unsnap the seat belts from the second seat belt latches. 2. Remove the seats and the risers from the vehicle. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 3. Remove the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 4. Remove the trim plates from the following: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 5. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 6. Remove the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 7. Remove the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 8. Remove the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 9. Remove the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 10. Remove the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. 11. The carpet bezels are retained by sonic weld and are not to be removed from the carpet. 12. Remove the carpet from the vehicle. Installation Procedure 1. Install the carpet into the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8918 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Tighten the bolt that retains each cargo net anchor to the floor 2 N.m (18 lb in). 3. Install the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 4. Install the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 5. Install the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 8. Install the trim plates at the following doors: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 9. Install the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 10. Install the seats and the risers. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 11. Snap the seat belts to the second seat belt latches. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8919 Carpet: Service and Repair Carpet Retainer Replacement Carpet Retainer Replacement Removal Procedure 1. Open the door(s). 2. Remove the screws that retain the left front door step trim plate to the vehicle. 3. Remove the screws that retain the right front door step trim plate to the vehicle. 4. Remove the screws that retain the sliding door step trim plate to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8920 5. Remove the screws that retain the rear trim plate to the vehicle. 6. Remove the trim plate from the vehicle. Installation Procedure 1. Install the trim plate to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the left front door step trim plate to the vehicle. Tighten the screws that retain the left front door step trim plate to 2 N.m (18 lb in). 3. Install the screws that retain the right front door step trim plate. Tighten the screws that retain the right front door step trim plate to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8921 4. Install the screws that retain the sliding door step trim plate to the vehicle. Tighten the screws that retain the sliding door step trim plate to 2 N.m (18 lb in). 5. Install the screws that retain the rear trim plate to the vehicle. Tighten the screws that retain the rear trim plate to 2 N.m (18 lb in). 6. Close the door(s). Mat Replacement - Stepwell Mat Replacement - Stepwell Removal Procedure 1. Remove the screws from the step plate cover. 2. Remove the step panel cover. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8922 1. Install the step panel cover. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). Mat/Carpet Replacement - Front Floor Mat/Carpet Replacement - Front Floor Removal Procedure 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Remove the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 3. Remove the trim plates from the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 5. Remove the throttle pedal guard. 6. Remove the screws from the center floor air duct. 7. Remove the center floor air duct. 8. Remove the front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 9. Remove the carpet/mat from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8923 1. Install the carpet/mat to the vehicle. 2. Install the center floor air duct. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the center floor air duct. Tighten the screws to the center floor air duct to 2 N.m (18 lb in). 4. Install the front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) . 5. Install the trim plates to the front door openings. Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 8. Install the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. Mat/Carpet Replacement - Rear Floor (B31) Mat/Carpet Replacement - Rear Floor (B31) Removal Procedure 1. Unsnap the seat belts from the second seat belt latches. 2. Remove the seats and the risers from the vehicle. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 3. Remove the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 4. Remove the trim plates from the following: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 5. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 6. Remove the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 7. Remove the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 8. Remove the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 9. Remove the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 10. Remove the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. 11. The carpet bezels are retained by sonic weld and are not to be removed from the carpet. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8924 12. Remove the carpet from the vehicle. Installation Procedure 1. Install the carpet into the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Tighten the bolt that retains each cargo net anchor to the floor 2 N.m (18 lb in). 3. Install the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 4. Install the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 5. Install the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 6. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 7. Install the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 8. Install the trim plates at the following doors: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 9. Install the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 10. Install the seats and the risers. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 11. Snap the seat belts to the second seat belt latches. Mat/Carpet Replacement - Rear Floor (B38) Mat/Carpet Replacement - Rear Floor (B38) Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8925 1. Remove the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. 2. Remove the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 3. Remove the trim plates from the following doors: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 4. Remove the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 5. Remove the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 6. Remove the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 7. Remove the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 8. Remove the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . 9. Remove the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. 10. The carpet bezels are retained by sonic weld and are not to be removed. 11. Remove the carpet from the vehicle. Installation Procedure 1. Install the carpet into the vehicle. 2. The carpet bezels are retained by sonic weld and are not to be removed. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolt that retains each cargo net anchor to the floor of the vehicle, if equipped. Tighten the bolt that retains each cargo net anchor to the floor 2 N.m (18 lb in). 4. Install the right body side trim panel. Refer to Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8926 5. Install the left body side trim panel. Refer to Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) . 6. Install the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) . 7. Install the cowl side panel trim. Refer to Trim Panel Replacement - Cowl Side (See: Trim Panel/Service and Repair/Trim Panel Replacement Cowl Side) . 8. Install the right front side door lock pillar garnish molding. Refer to Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) . 9. Install the trim plates from the following doors: * The front * The rear side * The rear Refer to Carpet Retainer Replacement (See: Carpet Retainer Replacement) . 10. Install the engine cover. Refer to Engine Cover Replacement (See: Access Cover/Service and Repair/Removal and Replacement/Engine Cover Replacement) . 11. Install the seats and the risers. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) in Seats. Mat/Carpet Replacement - Rear Wheelhouse Mat/Carpet Replacement - Rear Wheelhouse Removal Procedure 1. Remove the body side trim panel. Refer to the following procedures: * Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) * Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) * Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) 2. Remove the wheelhouse carpet from the vehicle. Installation Procedure 1. Install the wheelhouse carpet to the vehicle. 2. Install the body side trim panel. Refer to the following procedures: * Trim Panel Replacement - Body Side Front Lower (See: Trim Panel/Service and Repair/Trim Panel Replacement - Body Side Front Lower) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet Retainer Replacement > Page 8927 * Trim Panel Replacement - Left Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Left Body Side) * Trim Panel Replacement - Right Body Side (See: Trim Panel/Service and Repair/Trim Panel Replacement - Right Body Side) Mat Replacement - Side Door Stepwell Mat Replacement - Side Door Stepwell Removal Procedure 1. Remove the screws. 2. Remove the step panel cover. Installation Procedure 1. Install the step panel cover. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the step panel cover screws. Tighten the step panel cover screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Console: Description and Operation Overhead Console Description The overhead console is a convenience package that contains the following components: * A digital display (4) that provides: * The outside temperature * Eight primary compass readings indicating the direction the vehicle is travelling * Two switches (3) including: * An ON/OFF switch for the temperature/compass display * A U.S./METRIC switch that changes the temperature readout from degrees Fahrenheit (F) to degrees Celsius (C) * Two pivoting courtesy/map lamps (1) * A compartment (4) for a garage door opener with a transmitter (2) that can be activated by pressing the button (3) on the compartment door. * A compartment for storing sunglasses * A compartment for storing compact discs or tapes Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat Console: Service and Repair Center Console Replacement - Rear Seat Center Console Replacement - Rear Seat Removal Procedure 1. Remove the hog rings retaining the carpet to the seat cushion frame. 2. Remove the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. 3. Remove the bolts retaining the console to the seat cushion frame. 4. Remove the console and drink tray from the seat cushion frame. Installation Procedure 1. Install the console and drink tray to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts retaining the console and drink tray the seat cushion frame. Tighten the bolts retaining the console and drink tray to the seat cushion frame to 4 N.m (35 lb in). 3. Install the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8933 4. Install the hog rings in order to retain the carpet to the frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8934 Console: Service and Repair Console Replacement - Overhead Console Replacement - Overhead Removal Procedure Because the compass system is so complex and susceptible to outside influences, examine the system thoroughly before performing any repairs. Diagnose the system in an area free from potential interference, such as an open field. Recalibrate the system before performing any other repairs in order to verify the existence of a problem. 1. Remove the retaining screws from the overhead console. 1. Remove the dome lamp lens from the overhead console. 2. Remove the front screws from the overhead console. 3. Remove the rear screws from the overhead console. 2. Disconnect the electrical connectors. 3. Remove the overhead console as follows: 1. Swing the overhead console downward. 2. Pull the overhead console forward in order to clear the rear mounting tabs. Installation Procedure 1. Install the rear part of the overhead console by inserting the mounting tabs into the roof panel. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the overhead console retaining screws. Tighten the screws to the overhead console to 2 N.m (18 lb in). 1. Install the rear screws to the overhead console . Tighten the rear screws to the overhead console to 2 N.m (18 lb in). 2. Install the front screws to the overhead console . Tighten the front screws to the overhead console to 2 N.m (18 lb in). 3. Install the dome lamp lens to the overhead console . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8935 Console: Service and Repair Overhead Console - Courtesy Lamp Replacement COURTESY LAMP REPLACEMENT - OVERHEAD CONSOLE REMOVAL PROCEDURE 1. Unscrew the center of the lamp lens with a suitable flat bladed tool while pressing up on the lamp assembly. 2. Remove the lamp assembly. 3. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the new lamp in the assembly. 2. Install the lamp assembly into the cavity. 3. Turn the lamp assembly in order to latch the assembly into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8936 Console: Service and Repair Storage Tray Replacement - Right Front Seat Storage Tray Replacement - Right Front Seat Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . 2. Remove the passenger seat storage tray insert from the tray. 3. Remove the storage tray to track assembly retainers. 4. Remove the storage tray from the track assembly. 5. Remove the track assembly from the vehicle. Installation Procedure 1. Install the track assembly to the vehicle. 2. Install the passenger seat storage tray to the track assembly. 3. Install the storage tray to track assembly retainers. 4. Install the storage tray insert. 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8937 Console: Service and Repair Center Console Replacement - Rear Seat Center Console Replacement - Rear Seat Removal Procedure 1. Remove the hog rings retaining the carpet to the seat cushion frame. 2. Remove the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. 3. Remove the bolts retaining the console to the seat cushion frame. 4. Remove the console and drink tray from the seat cushion frame. Installation Procedure 1. Install the console and drink tray to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts retaining the console and drink tray the seat cushion frame. Tighten the bolts retaining the console and drink tray to the seat cushion frame to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8938 3. Install the carpet covering the center of the seat cushion frame along the rear edge of the seat, under the console. 4. Install the hog rings in order to retain the carpet to the frame. Console Replacement - Overhead Console Replacement - Overhead Removal Procedure Because the compass system is so complex and susceptible to outside influences, examine the system thoroughly before performing any repairs. Diagnose the system in an area free from potential interference, such as an open field. Recalibrate the system before performing any other repairs in order to verify the existence of a problem. 1. Remove the retaining screws from the overhead console. 1. Remove the dome lamp lens from the overhead console. 2. Remove the front screws from the overhead console. 3. Remove the rear screws from the overhead console. 2. Disconnect the electrical connectors. 3. Remove the overhead console as follows: 1. Swing the overhead console downward. 2. Pull the overhead console forward in order to clear the rear mounting tabs. Installation Procedure 1. Install the rear part of the overhead console by inserting the mounting tabs into the roof panel. 2. Connect the electrical connectors. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the overhead console retaining screws. Tighten the screws to the overhead console to 2 N.m (18 lb in). 1. Install the rear screws to the overhead console . Tighten the rear screws to the overhead console to 2 N.m (18 lb in). 2. Install the front screws to the overhead console . Tighten the front screws to the overhead console to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8939 3. Install the dome lamp lens to the overhead console . Overhead Console - Courtesy Lamp Replacement COURTESY LAMP REPLACEMENT - OVERHEAD CONSOLE REMOVAL PROCEDURE 1. Unscrew the center of the lamp lens with a suitable flat bladed tool while pressing up on the lamp assembly. 2. Remove the lamp assembly. 3. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the new lamp in the assembly. 2. Install the lamp assembly into the cavity. 3. Turn the lamp assembly in order to latch the assembly into place. Storage Tray Replacement - Right Front Seat Storage Tray Replacement - Right Front Seat Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8940 2. Remove the passenger seat storage tray insert from the tray. 3. Remove the storage tray to track assembly retainers. 4. Remove the storage tray from the track assembly. 5. Remove the track assembly from the vehicle. Installation Procedure 1. Install the track assembly to the vehicle. 2. Install the passenger seat storage tray to the track assembly. 3. Install the storage tray to track assembly retainers. 4. Install the storage tray insert. 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Seats/Service and Repair/Seat Replacement - Bucket) . Trim Panel Replacement - Rear Door (Cargo Doors) Trim Panel Replacement - Rear Door (Cargo Doors) Removal Procedure 1. Remove the window garnish molding. Refer to Window Garnish Molding Replacement (See: Trim Panel/Service and Repair/Window Garnish Molding Replacement) . 2. Remove the screws. 3. Remove the trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8941 Installation Procedure 1. Install the trim panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the trim panel screws. Tighten the trim panel screws to 2 N.m (18 lb in). 3. Install the window garnish molding. Refer to Window Garnish Molding Replacement (See: Trim Panel/Service and Repair/Window Garnish Molding Replacement) . Trim Panel Replacement - Rear Door (E54) Trim Panel Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the lace. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console Replacement - Rear Seat > Page 8942 2. Use J 38778 in order to remove the trim panel. Installation Procedure 1. Install the trim panel to the door. 2. Install the lace. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 8948 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Compartment Replacement - IP Forward Extension Removal Procedure 1. Remove the instrument panel extension trim plate. Refer to IP Extension Trim Plate Replacement (See: Dashboard / Instrument Panel/Service and Repair/IP Extension Trim Plate Replacement) . 2. Squeeze the two retainers and pull out in order to remove the storage compartment. Installation Procedure 1. Snap the storage compartment into place. 2. Install the instrument panel extension trim plate. Refer to IP Extension Trim Plate Replacement (See: Dashboard / Instrument Panel/Service and Repair/IP Extension Trim Plate Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Replacement Removal Procedure 1. Remove the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair) . 2. Remove the overhead console, if equipped. Refer to Console Replacement - Overhead (See: Console/Service and Repair/Console Replacement Overhead) . 3. Refer to the following procedures in order to remove the necessary moldings: * Garnish Molding Replacement - Rear Upper (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) * Garnish Molding Replacement - Side Door Opening Frame (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Side Door Opening Frame) * Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) * Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) * Trim Replacement - Third Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Left) * Trim Replacement - Third Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Left) * Trim Replacement - Fourth Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Right) 4. Release the front headliner from the roof panel by separating the retaining strips. 5. Remove the front headliner from the vehicle. 6. Remove the right seat belt retractor. Refer to Seat Belt Retractor Replacement - Right Front in Seat Belts. 7. Remove the dome lamp from the rear headliner. Refer to Dome Lamp Replacement in Lighting Systems. 8. Remove the sliding door track garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) . 9. Remove the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair) . 10. Remove the 2 push-in retainers (4) at the front edge of the rear headliner (2). 11. Detach the rear headliner (2) from the retaining strips (3). 12. Remove the rear headliner (2) from the roof panel (1). 13. With the aid of an assistant, remove the rear headliner from the vehicle. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8955 1. In order to install the rear headliner to the roof panel perform the following: 1. With the aid of an assistant, position the rear headliner to the roof panel. 2. Attach the rear headliner to the retaining strips. 3. Install the 2 push-in retainers (4) at the front edge of the rear headliner. 2. Install the coat hooks. Refer to Coat Hook Replacement (See: Service and Repair) . 3. Install the sliding door track garnish molding. Refer to Garnish Molding Replacement - Sliding Door (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Sliding Door) . 4. Install the dome lamp to the rear headliner. Refer to Dome Lamp Replacement in Lighting Systems. 5. Install the right seat belt retractor. Refer to Seat Belt Retractor Replacement - Right Front in Seat Belts. 6. Position the front headliner to the roof panel. 7. Fasten the front headliner to the roof panel, ensuring that the retaining strips are fully engaged. 8. Install the front side door opening frame garnish molding. Refer to Garnish Molding Replacement - Side Door Opening Frame (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Side Door Opening Frame) . 9. Refer to the following procedures in order to install the necessary moldings: * Trim Replacement - Fourth Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Fourth Pillar Left) * Trim Replacement - Third Pillar Right (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Right) * Trim Replacement - Third Pillar Left (See: Trim Panel/Service and Repair/Trim Replacement Third Pillar Left) * Garnish Molding Replacement - RF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - RF Lock Pillar) * Garnish Molding Replacement - LF Lock Pillar (See: Trim Panel/Service and Repair/Garnish Molding Replacement - LF Lock Pillar) * Garnish Molding Replacement - Rear Upper (See: Trim Panel/Service and Repair/Garnish Molding Replacement - Rear Upper) * Install the overhead console. Refer to Console Replacement - Overhead (See: Console/Service and Repair/Console Replacement - Overhead) . * Install the sunshades. Refer to Sunshade Replacement (See: Sun Visor/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair Passenger Assist Handle: Service and Repair IP Assist Handle Replacement Removal Procedure 1. Remove the inflatable restraint IP module. Refer to Inflatable Restraint Instrument Panel Module Replacement in SIR. 2. Remove the nuts from the assist handle. 3. Remove the assist handle. Installation Procedure 1. Install the assist handle to the instrument panel. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the assist handle nuts. Tighten the assist handle nuts to 8 N.m (71 lb ft). 3. Install the inflatable restraint IP module. Refer toInflatable Restraint Instrument Panel Module Replacement in SIR. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair Sunshade Replacement Removal Procedure 1. Remove the sunshade retaining screws, unplug the wiring harness (if equipped). 2. Remove the sunshade from the vehicle. Installation Procedure 1. Install the sunshade to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the sunshade retaining screws, connect the sunshade wiring harness (if equipped). Tighten the sunshade retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar Trim Panel: Service and Repair Garnish Molding Replacement - LF Lock Pillar Garnish Molding Replacement - LF Lock Pillar Removal Procedure 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. Installation Procedure 1. Install the garnish molding to the pillar: 1. Align the locator pin with the pillar. 2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. Refer toShoulder Belt Guide Adjuster Replacement - Front in Seat Belts. Notice: Refer toFastener Notice in Cautions and Notices. 3. Install the garnish molding retaining screw. Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8966 Trim Panel: Service and Repair Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure 1. Remove the interior handle screw cover (12). 2. Remove the screws (11). 3. Remove the handle (10) and the escutcheon (9). 4. Remove the garnish molding screws (3). 5. Remove the garnish molding (2). Installation Procedure 1. Install the garnish molding (2). Install the locator pins into the locator hole on the liftgate. Notice: Refer to Fastener Notice in Caution and Notices. 2. Install the garnish molding screws (3). Tighten the garnish molding screws to 2 N.m (18 lb in). 3. Install the handle escutcheon (9) and the handle (10). 4. Install the interior handle. Tighten the interior handle screws to 6 N.m (53 lb in). 5. Install the interior handle screw covers (12). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8967 Trim Panel: Service and Repair Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Removal Procedure 1. Remove the screws that retain the door frame garnish molding to the vehicle. 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the molding to the roof. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the roof retaining screws. Tighten the roof retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8968 Trim Panel: Service and Repair Garnish Molding Replacement - RF Lock Pillar Garnish Molding Replacement - RF Lock Pillar Removal Procedure 1. Remove the garnish molding screws. 2. Remove the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Remove the bolts that retain the assist handle to the pillar. 4. Pull back on the garnish molding to release the fasteners. 5. Remove the garnish molding. 6. Disconnect the electrical connector from the rear side door stepwell lamp. Installation Procedure 1. Connect the electrical connector to the rear side door stepwell lamp. 2. Install the molding to the pillar: 1. Align the fasteners with the slots in the pillar. 2. Press firmly until the fasteners are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8969 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts that retain the assist handle to the pillar. Tighten the bolts that retain the assist handle to the pillar to 8 N.m (71 lb in). 4. Install the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 5. Install the retaining screws. Tighten the retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8970 Trim Panel: Service and Repair Garnish Molding Replacement - LF Lock Pillar Garnish Molding Replacement - LF Lock Pillar Removal Procedure 1. Remove the retaining screw from the garnish molding. 2. Remove the driver's side seat belt upper mounting bolt. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Pull back on the garnish molding in order to release the fasteners. 4. Remove the garnish molding from the pillar. Installation Procedure 1. Install the garnish molding to the pillar: 1. Align the locator pin with the pillar. 2. Press the locator pin firmly into place, seating all fasteners. 2. Install the driver's seat belt upper mounting bolt. Refer toShoulder Belt Guide Adjuster Replacement - Front in Seat Belts. Notice: Refer toFastener Notice in Cautions and Notices. 3. Install the garnish molding retaining screw. Tighten the garnish molding retaining screw to 2 N.m (18 lb in). Garnish Molding Replacement - Lift Gate Garnish Molding Replacement - Lift Gate Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8971 1. Remove the interior handle screw cover (12). 2. Remove the screws (11). 3. Remove the handle (10) and the escutcheon (9). 4. Remove the garnish molding screws (3). 5. Remove the garnish molding (2). Installation Procedure 1. Install the garnish molding (2). Install the locator pins into the locator hole on the liftgate. Notice: Refer to Fastener Notice in Caution and Notices. 2. Install the garnish molding screws (3). Tighten the garnish molding screws to 2 N.m (18 lb in). 3. Install the handle escutcheon (9) and the handle (10). 4. Install the interior handle. Tighten the interior handle screws to 6 N.m (53 lb in). 5. Install the interior handle screw covers (12). Garnish Molding Replacement - Rear Upper Garnish Molding Replacement - Rear Upper Removal Procedure 1. Remove the screws that retain the door frame garnish molding to the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8972 2. Remove the door frame garnish molding. 3. Disconnect the electrical connector. Installation Procedure 1. Connect the electrical connector. 2. Install the molding to the roof. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the roof retaining screws. Tighten the roof retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - RF Lock Pillar Garnish Molding Replacement - RF Lock Pillar Removal Procedure 1. Remove the garnish molding screws. 2. Remove the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 3. Remove the bolts that retain the assist handle to the pillar. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8973 4. Pull back on the garnish molding to release the fasteners. 5. Remove the garnish molding. 6. Disconnect the electrical connector from the rear side door stepwell lamp. Installation Procedure 1. Connect the electrical connector to the rear side door stepwell lamp. 2. Install the molding to the pillar: 1. Align the fasteners with the slots in the pillar. 2. Press firmly until the fasteners are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the bolts that retain the assist handle to the pillar. Tighten the bolts that retain the assist handle to the pillar to 8 N.m (71 lb in). 4. Install the front passenger's seat belt upper retainer. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 5. Install the retaining screws. Tighten the retaining screws to 2 N.m (18 lb in). Garnish Molding Replacement - Side Door Opening Frame Garnish Molding Replacement - Side Door Opening Frame Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the garnish molding screw. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8974 2. Use the J 38778 in order to remove the door opening garnish molding on the retainers at the windshield pillar. 3. Remove the molding from one retainer in the center of the door opening. This retainer will stay with the vehicle, not the molding. 4. Slide the molding up past the following components in order to remove the molding from the vehicle: * The cowl side trim panel * The knee bolster * The instrument panel Installation Procedure 1. Slide the molding past the following components in order to install the molding to the vehicle: * The instrument panel * The knee bolster * Behind the cowl side panel trim 2. Align the fasteners at the windshield pillar. 3. Press the fasteners into place until the fasteners seat fully. 4. Install the tab on the molding in the clip in the center of the door opening. Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the screw that retains the end of the molding to the vehicle. Tighten the screw that retains the end of the molding to 2 N.m (18 lb in). Garnish Molding Replacement - Sliding Door Garnish Molding Replacement - Sliding Door Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the swing-out window latch from the door, if equipped. Refer to Window Replacement Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) . 2. Remove the door handle bezel screws. 3. Remove the door handle bezel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8975 4. Use J 38778 in order to release the molding retainers. Installation Procedure 1. Install the door garnish molding to the vehicle: 1. Align the retainers to the holes in the door. 2. Press the panel in order to engage the retainers into the door. 2. Install the door handle bezel to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the door handle bezel screws. Tighten the door handle bezel screws to 2 N.m (18 lb in). 4. Install the swing-out window latch to the door, if equipped. Refer to Window Replacement Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) . Garnish Molding Replacement - Upper Roller Track Garnish Molding Replacement - Upper Roller Track Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the retaining screws from the upper garnish molding. 2. Use J 38778 in order to release the molding retainers. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8976 1. Align the fasteners with the slots in the body. 2. Press the panel firmly into position, ensuring that all fasteners are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the retaining screws to the upper garnish molding. Tighten the retaining screws to the upper garnish molding to 2 N.m (18 lb in). Trim Panel Replacement - Body Side Front Lower Trim Panel Replacement - Body Side Front Lower Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the intermediate seat. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. 2. Remove the driver's door stepwell lamp cover retaining screw. 3. Remove the stepwell lamp assembly from the body side lower storage pocket. 4. Use the J 38778 in order to remove the body side front lower trim panel from the vehicle. Installation Procedure 1. Install the body side front lower trim panel to the vehicle: 1. Align the fasteners. 2. Snap the fasteners into place. 2. Install the driver's door stepwell lamp assembly to the body side lower storage pocket. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8977 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the stepwell lamp cover retaining screw. Tighten the stepwell lamp cover retaining screw to 2 N.m (18 lb in). 4. Install the intermediate seat. Refer to Seat Replacement - Rear Bench (See: Seats/Service and Repair/Seat Replacement - Rear Bench) in Seats. Trim Panel Replacement - Body Side Front Upper Trim Panel Replacement - Body Side Front Upper Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 2. Remove the intermediate swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 3. Remove the retaining screw at the B pillar. 4. Use the J 38778 in order to remove the body side front upper trim panel from the vehicle. 5. Disconnect the electrical connector from the rear audio controls, if equipped. 6. Remove the rear audio controls from the trim panel. Refer to Audio Control Replacement - Rear Seat in Entertainment. Installation Procedure 1. Install the rear audio controls to the trim panel, if equipped. Refer to Audio Control Replacement - Rear Seat in Entertainment. 2. Connect the electrical connector to the rear audio controls. 3. Install the body side front upper trim panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the retaining screw to the B pillar. Tighten the retaining screw to the B pillar to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8978 5. Install the intermediate swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 6. Install the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . Trim Panel Replacement - Cowl Side Trim Panel Replacement - Cowl Side Removal Procedure 1. Remove the driver's or the passenger's knee bolster. Refer to Knee Bolster Replacement - Left (See: Dashboard / Instrument Panel/Service and Repair/Knee Bolster Replacement - Left) orKnee Bolster Replacement - Right (See: Dashboard / Instrument Panel/Service and Repair/Knee Bolster Replacement - Right) in Instrument Panel, Gages and Console. 2. Remove the screws that retain the panel to the cowl side. 3. Remove the trim panel from the vehicle. Installation Procedure 1. Install the trim panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the trim panel to the cowl side. Tighten the screws that retain the trim panel to the cowl side to 2 N.m (18 lb in). 3. Install the driver's or the passenger's knee bolster. Refer to Knee Bolster Replacement - Left (See: Dashboard / Instrument Panel/Service and Repair/Knee Bolster Replacement - Left) orKnee Bolster Replacement - Right (See: Dashboard / Instrument Panel/Service and Repair/Knee Bolster Replacement - Right) in Instrument Panel, Gages and Console. Trim Panel Replacement - Left Body Side Trim Panel Replacement - Left Body Side Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8979 1. Remove the quarter panel swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 2. Remove the third and the fourth pillar trim. Refer to Trim Replacement - Third Pillar Left (See: Trim Replacement - Third Pillar Left) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 3. Remove the rear clip on the body side front lower trim panel. Refer to Trim Panel Replacement Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 4. Remove the rear clips on the body side front trim panel, upper and lower. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) and Trim Panel Replacement - Body Side Front Upper (See: Trim Panel Replacement - Body Side Front Upper) . 5. Remove the seat belt upper anchor. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 6. Remove the cargo net bolt. 7. Use the J 38778 in order to remove the clips that retain the trim panel to the vehicle. 8. Pull the trim panel back from the body side panel. * Remove the seat belt retractor from the body side panel. Refer to appropriate procedure in Seat Belts: * Seat Belt Retractor Replacement - Left Front * Seat Belt Retractor Replacement - Right Front * Seat Belt Retractor Replacement - Right Rear * Seat Belt Retractor Replacement - No. 2 Left Rear * Seat Belt Retractor Replacement - No. 2 Right Rear 9. Squeeze the storage tray from underneath and press out in order to remove the storage tray from the trim panel. 10. Remove the trim panel from the vehicle. Installation Procedure 1. Install the panel to the vehicle. 2. Install the retractor through the trim panel. 3. Press the storage tray into place in order to install the storage tray to the trim panel. 4. Install the seat belt retractor to the body side panel. 5. Install the trim panel to the body side panel: 1. Align the retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the cargo net bolt. Tighten the cargo net bolt to 2 N.m (18 lb in). 7. Install the seat belt upper anchor. 8. Remove the rear clip on the body side front lower trim panel. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) . 9. Install the rear clips on the body side front trim panel, upper and lower. Refer to Trim Panel Replacement - Body Side Front Lower (See: Trim Panel Replacement - Body Side Front Lower) and Trim Panel Replacement - Body Side Front Upper (See: Trim Panel Replacement - Body Side Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8980 Front Upper) . 10. Install the third and the fourth pillar trim. Refer to Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 11. Install the quarter panel swing out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. Trim Panel Replacement - Right Body Side Trim Panel Replacement - Right Body Side Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the C and the D pillar trim. Refer to Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) and Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) . 2. Remove the jack access panel. 3. Remove the upper and the lower belt anchors. Refer to Seat Belt Retractor Replacement - No. 2 Left Rear or Seat Belt Retractor Replacement No. 2 Right Rear in Seat Belts. 4. Remove the cargo net bolt. 5. Remove the screw that retains the panel to the C pillar. 6. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw that retains the panel to the C pillar. Tighten the screw that retains the panel to the C pillar to 2 N.m (18 lb in). 3. Install the cargo net bolt. Tighten the cargo net bolt to 2 N.m (18 lb in). 4. Install the jack access panel. 5. Install the upper and the lower mounting bolts for the rear seat belt. Refer to Seat Belt Retractor Replacement - No. 2 Left Rear Seat Belt Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8981 Retractor Replacement - No. 2 Right Rear in seat belts. 6. Install the C and the D pillar trim. Refer to the appropriate procedure: * Trim Replacement - Third Pillar Right (See: Trim Replacement - Third Pillar Right) * Trim Replacement - Fourth Pillar Left (See: Trim Replacement - Fourth Pillar Left) Trim Panel Vent Replace - Body Side Front Lower Trim Panel Vent Replace - Body Side Front Lower Removal Procedure Pull out ward on the vent in order to remove the vent from the trim panel. Installation Procedure Press the vent inward in order to install the vent to the trim panel. Trim Replacement - Fourth Pillar Left Trim Replacement - Fourth Pillar Left Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the rear door(s). 2. Remove the screws from the panel in the rear door opening. 3. Use J 38778 in order to release the fasteners that retain the panel to the vehicle. 4. Disconnect the speaker electrical connector, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8982 Installation Procedure 1. Connect the speaker electrical connector, if equipped. 2. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the panel in the rear door opening. Tighten the screws to the panel in the rear door opening to 2 N.m (18 lb in). Trim Replacement - Fourth Pillar Right Trim Replacement - Fourth Pillar Right Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the rear door(s). 2. Remove the screws from the panel in the rear door opening. 3. Use J 38778 in order to release the fasteners that retain the panel to the vehicle. 4. Disconnect the speaker electrical connector, if equipped. Installation Procedure 1. Connect the speaker electrical connector, if equipped. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8983 2. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel down in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws to the panel in the rear door opening. Tighten the screws to the panel in the rear door opening to 2 N.m (18 lb in). Trim Replacement - Third Pillar Left Trim Replacement - Third Pillar Left Tools Required J 38778 Door Pad Trim and Garnish Clip Remover Removal Procedure 1. Remove the seat belt upper mount. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. 2. Remove the retaining screw. 3. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8984 2. Install the retaining screw. Tighten the retaining screw to 2 N.m (18 lb in). 3. Install the seat belt upper mount. Refer to Shoulder Belt Guide Adjuster Replacement - Front in Seat Belts. Trim Replacement - Third Pillar Right Trim Replacement - Third Pillar Right Tools Required J 38778 Door Trim Pad and Garnish Clip Remover. Removal Procedure 1. Remove the C- pillar retaining screw. 2. Use the J 38778 in order to release the fasteners that retain the panel to the vehicle. Installation Procedure 1. Install the panel to the vehicle: 1. Align the C- pillar retaining clips with the holes in the body. 2. Press the panel in order to seat the fasteners into place. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the C- pillar retaining screw. Tighten the C- pillar retaining screw to 2 N.m (18 lb in). Window Garnish Molding Replacement Window Garnish Molding Replacement Removal Procedure 1. Remove the swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8985 2. Remove the screws that retain the right molding on the sides and the bottom. 3. Remove the screws that retain the left molding on the sides and the bottom. 4. Remove the molding from the door in the area of the retainers. There are 2 retainers on top, one in the center of the panel, and 6 around the outside edge. Installation Procedure 1. Install the left molding to the door: 1. Place the retainers into the holes. 2. Press on the panel at the retainer locations until the retainers are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Garnish Molding Replacement - LF Lock Pillar > Page 8986 2. Install the right molding to the door: 1. Place the retainers into the holes. 2. Press on the panel at the retainer locations until the retainers are fully seated. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the panel to the door. Tighten the screws that retain the panel to the door to 2 N.m (18 lb in). 4. Install the swing-out window latch. Refer to Window Replacement - Swing Out (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Window Replacement - Swing Out) in Stationary Windows. 5. Ensure that the weatherstrip fits into the corner and matches the corner of the radius of the body flange. 6. Ensure that the weatherstrip is seated completely onto the flange in all areas, resulting in a smooth, vinyl trim around the entire door opening. Important: When using the rubber mallet, the weatherstrip must be hit square to the flange. Otherwise, an undesirable spreading of the carrier will occur, resulting in reduced retention. 7. Ensure that there is no distortion or excessive spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. 8. Lubricate the weatherstrip with GM Weatherstrip Silicone Lubricant P/N 12345579 or equivalent. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Outside Handle and Lock Cylinder Replacement Removal Procedure Important: If door lock cylinders require replacement for any reason, apply a coating of GM P/N 12346241 or equivalent lubricant inside of the lock case and the cylinder keyway prior to assembling and installing the cylinder. 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Use a sharp bladed tool in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 3. Remove the access hole plug (1). 4. Remove the lock rod from the door handle. 5. Remove the nuts from the door handle (4). 6. Remove the door handle from the door (2). 7. Remove the lock rod from the lock cylinder (3). 8. Remove the lock cylinder retainer. 9. Remove the lock cylinder and the gasket (5) from the door. Installation Procedure Important: Install new plastic retainer clips whenever the lock rods are removed. 1. Install the gasket (5) and the lock cylinder to the door. 2. Install the lock cylinder retainer . 3. Install the lock rod to the lock cylinder. 4. Install the handle to the door (2). Notice: Refer to Fastener Notice in Cautions and Notices. 5. Install the nuts to the door handle (4). Tighten the nuts to the door handle to 6 N.m (53 lb in). 6. Install the door handle lock rod to the handle. 7. Install the access hole plug (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Page 8992 8. Install the water deflector. Refer to Water Deflector Replacement - Front Door. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 9. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8997 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8998 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 8999 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations > Page 9004 Antenna - Keyless Entry: Service and Repair REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate. 2. Remove the instrument panel cluster. 3. Disconnect the remote keyless entry antenna (1) from the receiver (2). 4. Remove the remote keyless entry antenna (1) from the carrier. 5. Remove the remote keyless entry antenna from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Locations > Page 9005 1. Install the remote keyless entry antenna to the vehicle. 2. Install the remote keyless entry antenna (1) to the carrier. 3. Connect the remote keyless entry antenna (1) to the receiver (2). 4. Install the instrument panel cluster. 5. Install the instrument panel cluster trim plate. 6. Reprogram the transmitter. Refer to Transmitter Programming. See: Testing and Inspection/Programming and Relearning 7. Verify that the system operates properly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 9009 Remote Control Door Lock Receiver (RCDLR) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 9010 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the left knee bolster. 2. Disconnect the remote keyless entry antenna (2) from the receiver (5). 3. Disconnect the remote keyless entry electrical connector (4) from the receiver (5). 4. Remove the remote keyless entry module screws from the bracket (3). 5. Remove the remote keyless entry module from the carrier. INSTALLATION PROCEDURE 1. Install the remote keyless entry module to the carrier. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the remote keyless entry module screws to the bracket (3). Tighten Tighten the remote keyless entry module screws to the bracket (3) to 2 N.m (18 lb in). 3. Connect the remote keyless entry antenna (2) to the receiver (5). 4. Connect the remote keyless entry electrical connector (4) to the receiver (5). 5. Install the left knee bolster. 6. Reprogram the transmitter. See: Testing and Inspection/Programming and Relearning Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Locations > Page 9011 7. Verify that the system operates properly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT REMOVAL PROCEDURE 1. Insert a small coin between the 2 halves of the transmitter case at the slot provided near the key ring hole. 2. Twist the coin in order to open the case. 3. Open the transmitter case. 4. Remove the battery (2). INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair > Page 9016 1. Install the battery (2) with the positive (+) side down. Use one 3 V CR2032 battery (or the equivalent). 2. Close the transmitter case (6, 4). 3. Ensure the seal is in position. Align the 2 halves of the case and snap the two halves together. 4. Synchronize the transmitter. Refer to Transmitter Synchronization. 5. Replace the batteries when the range of the transmitter decreases to less than 7 m (23 ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9021 Door Lock Relay Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver Door Lock Switch - Front Passenger Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9025 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw at the front edge of the accessory switch mount plate. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 9026 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Testing and Inspection Trunk / Liftgate Lock Cylinder: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Trunk/Liftgate, Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Testing and Inspection > Page 9030 Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Lift Gate Removal Procedure 1. Remove the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Disconnect the electrical connector. 3. Remove the rear wiper motor from the liftgate. 4. Remove the lock cylinder retainer. 5. Remove the lock cylinder from the liftgate. Installation Procedure 1. Install the lock cylinder to the liftgate. 2. Install the lock cylinder retainer. 3. Install the rear wiper motor to the liftgate. 4. Connect the electrical connector. 5. Install the liftgate garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the Driver Information Center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 9040 Memory Positioning Systems: Description and Operation Vehicle Personalization PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission it left the factory programmed to lock all doors when the vehicle speed is greater than 24 km/h (15 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 second limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. ^ The following is a list of available programming options: ^ All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. ^ All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. ^ All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. ^ No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 9050 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 9056 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9066 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9067 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9068 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 9069 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts Paint: Application and ID Paint Code Charts Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 9072 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 9073 Paint: Application and ID Parts ID Label Location LABEL - SERVICE PARTS ID Label - Service Parts ID The Service Parts Identification Label aids the service personnel in identifying the parts and options originally installed on the vehicle. The label is located on the front passenger door frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 9074 Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Caution: Refer to Eye Protection Caution in Cautions and Notices. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D-99 identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers. If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clearcoat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel.) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: * Lifting of primer coats caused by overly aggressive solvents in subsequent layers * Loss of adhesion between layers due to incompatibility of resin systems * Solvent popping or pinholing due to inappropriate solvent selection * Poor through-curing due to incompatible hardener resins or insufficient reactivity * Gloss reduction due to incompatible resins and/or solvents * Poor color accuracy due to pigment interactions with incompatible resins and/or solvents * Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Code Charts > Page 9075 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID (See: Application and ID/Label - Service Parts ID) in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair Support Replacement - Center Removal Procedure 1. Remove the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. 2. Remove the outside air temperature sensor and wiring, if equipped. 3. Remove the center support bracket bolts. 4. Remove the support bracket from the vehicle. Installation Procedure 1. Install the center support bracket to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the support bracket bolts. Tighten the bolts to 25 N.m (18 lb ft). 3. Install the outside air temperature sensor and wiring, if equipped. 4. Install the grille. Refer to Grille Replacement (See: Grille/Service and Repair/Grille Replacement) in Exterior Trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9083 Door Lock Relay Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Procedures Luggage Rack: Procedures LUGGAGE CARRIER REPLACEMENT REMOVAL PROCEDURE 1. Remove the rubber side rail cap from the center support. 2. Remove the bolts from the center supports. 3. Remove the bolts from the end supports. 4. Remove the luggage carrier as an assembly from the roof with an assistant. 5. Remove the side rail support gaskets. 6. Remove the screws from the side rail supports. 7. Remove the side rail supports from the side rails. 8. Remove the screws from the cross rails. 9. Remove the cross rails from the sliders. 10. Remove the screws from the sliders and the lock plates. 11. Remove the sliders from the slots in the side rails. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Procedures > Page 9090 INSTALLATION PROCEDURE 1. Install the sliders into the slots in the side rails. 2. Install the screws into the sliders and the lock plates. 3. Install the cross rails onto the sliders. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the cross rails. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the side rail supports to the side rails. 6. Install the screws to the side rail supports. Tighten Tighten the screws to 2 N.m (18 lb in). 7. Install the side rail support gaskets to the roof. 8. Install the luggage carrier as an assembly onto the roof with an assistant. 9. Install the screws to the end supports. Tighten Tighten the screws to 3 N.m (27 lb in). 10. Install the screws into the center supports. Tighten Tighten the screws to 3 N.m (27 lb in). 11. Install the rubber side rail cap onto the center support. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Procedures > Page 9091 Luggage Rack: Removal and Replacement Luggage Carrier Replacement Removal Procedure 1. Remove the rubber side rail cap from the center support. 2. Remove the bolts from the center supports. 3. Remove the bolts from the end supports. 4. Remove the luggage carrier as an assembly from the roof with an assistant. 5. Remove the side rail support gaskets. 6. Remove the screws from the side rail supports. 7. Remove the side rail supports from the side rails. 8. Remove the screws from the cross rails. 9. Remove the cross rails from the sliders. 10. Remove the screws from the sliders and the lock plates. 11. Remove the sliders from the slots in the side rails. Installation Procedure 1. Install the sliders into the slots in the side rails. 2. Install the screws into the sliders and the lock plates. 3. Install the cross rails onto the sliders. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Procedures > Page 9092 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the screws to the cross rails. Tighten the screws to 2 N.m (18 lb in). 5. Install the side rail supports to the side rails. 6. Install the screws to the side rail supports. Tighten the screws to 2 N.m (18 lb in). 7. Install the side rail support gaskets to the roof. 8. Install the luggage carrier as an assembly onto the roof with an assistant. 9. Install the screws to the end supports. Tighten the screws to 3 N.m (27 lb in). 10. Install the screws into the center supports. Tighten the screws to 3 N.m (27 lb in). 11. Install the rubber side rail cap onto the center support. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement - Rear Seat Head Rest: Service and Repair Head Restraint Replacement - Rear Seat Head Restraint Replacement - Rear Seat Removal Procedure 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2. Have the assistant lift up on the headrest. 3. Remove the headrest. 3. If working alone, proceed as follows: 1. Using 1 hand, depress 1 locking tab. Use the other hand to lift up on the same side of the headrest. 2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3. Remove the headrest from the seat back. Installation Procedure 1. Align the post of the headrest with the holes in the seat back. 2. Manipulate the posts within the seat back until the posts fall into the holes in the headrest bushing. 3. Press the headrest all the way into the seat. 4. Raise the headrest in order to verify that the locks are engaged. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement - Rear Seat > Page 9098 Head Rest: Service and Repair Head Restraint Replacement (YC6) Head Restraint Replacement (YC6) Removal Procedure 1. Raise the headrest. 2. Using a pointed tool, release the retainer on either side of the headrest while pulling up on the headrest. 3. Remove the headrest from the seat. Installation Procedure 1. Align the headrest posts with the openings in the seat back. 2. Press the headrest down into the seat to the fully lowered position. 3. Pull the headrest back up in order to assure the retainers are functioning properly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement - Rear Seat > Page 9099 Head Rest: Service and Repair Head Restraint Replacement (YC7) Head Restraint Replacement (YC7) Removal Procedure 1. Raise the headrest. 2. If an assistant is available, proceed as follows: 1. Press the locking tabs on the headrest bushings in and down at a 45 degree angle in order to release them. 2. Have the assistant lift up on the headrest. 3. Remove the headrest. 3. If working alone, proceed as follows: 1. Using one hand, depress one locking tab. Use the other hand to lift up on that side of the headrest. 2. While continuing to pull up on the headrest, depress the locking tab on the other side of the headrest bushing. 3. Remove the headrest from the seat back. Installation Procedure 1. Install the headrest to the seat back. 2. Push down on the headrest. 3. While continuing to press down on the headrest, depress the locking tab on the other side of the headrest bushing. 4. The locking tabs should click into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement - Rear Seat > Page 9100 Head Rest: Service and Repair Bucket Seat Head Restraint Bushing Replacement Bucket Seat Head Restraint Bushing Replacement Removal Procedure 1. Remove the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back/Service and Repair/Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back/Service and Repair/Seat Back Cover and Pad Replacement (YC7)) . 2. Remove the headrest bushings from the seat back frame as follows: 1. Squeeze together the retaining tabs at the base of the bushing. 2. Remove the bushing by lifting the bushing up. Installation Procedure 1. Install the headrest bushings by pressing the bushings into the seat back frame until the retaining tabs snap into place. 2. Install the seat back trim cover and pad assembly. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back/Service and Repair/Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back/Service and Repair/Seat Back Cover and Pad Replacement (YC7)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the Driver Information Center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 9109 Memory Positioning Systems: Description and Operation Vehicle Personalization PROGRAMMABLE AUTOMATIC DOOR LOCKS (IF EQUIPPED) If the vehicle has power door locks, it is equipped with a feature that enables you to program the power door locks. The vehicle left the factory programmed to automatically lock all doors when the vehicle is shifted out of PARK (P), and all doors unlock when the vehicle is shifted into PARK (P). If the vehicle has a manual transmission it left the factory programmed to lock all doors when the vehicle speed is greater than 24 km/h (15 mph) for two seconds, and unlock all doors once the key is removed from the ignition. The following instructions detail how enter the programming mode for the power door lock feature: 1. Begin with the ignition in OFF. Then pull the signal/multifunction lever all the way toward you and hold it there while you perform the next step. 2. Turn the key to RUN and OFF twice. Then, with the key in OFF, release the turn signal/multifunction lever. Once you do this you will hear the lock switch lock and unlock. 3. You are now ready to program the automatic door locks. Select one of the following four programming options and follow the instructions. You will have 30 seconds to complete programming. If you exceed the 30 second limit, The locks will automatically lock and unlock to indicate that you have left the program mode. If this occurs, repeat the procedure beginning with step 1. You can exit the program mode any time by turning the ignition to RUN. If the LOCK/UNLOCK switches are not pressed while in the programming mode, the current LOCK/UNLOCK mode will not be modified. ^ The following is a list of available programming options: ^ All doors lock/Only the driver's door unlocks: Press the lock side of the power door lock switch on the door panel once, and then the unlock side once. ^ All doors lock/All doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side twice. ^ All doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel once, and then the unlock side three times. ^ No doors lock/None of the doors unlock: Press the lock side of the power door lock switch on the door panel twice. This turns off the automatic door lock feature. ADDITIONAL INFORMATION Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 9113 Power Seat Motor: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9117 Seat Adjuster Switch - Driver Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9118 Power Seat Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9119 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 9120 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front Seat Back: Service and Repair Seat Back Frame Replacement - Front Seat Back Frame Replacement - Front Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat back cover and pad . Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 3. Remove the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 4. Remove the bolts from the seat back hinges on the right and left side. 5. Remove the seat back frame. Installation Procedure 1. Install the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts to the seat back hinges on the right and left side. Tighten the bolts to the seat back hinges on the right and left side to 30 N.m (22 lb in). 3. Install the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9125 4. Install the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9126 Seat Back: Service and Repair Seat Back Hinge Replacement - Front (YC5 and YC6) Seat Back Hinge Replacement - Front (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the seat riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat cover J-hook from the seat cushion frame: 1. Remove the J-hook at the rear of the seat. 2. Remove the J-hook on the side of the seat containing the seat back hinge. 3. Remove the J-hook that retains the cover to the carpet on the back of the seat on the side of the seat containing the seat back hinge. Important: Note the position and length of all the bolts removed. This will assist with reassembly. 3. Remove the bolts that retain the seat back hinge to the seat cushion frame. 4. Remove the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 5. Lift the seat back cover and pad above the bolts that retain the seat back hinge to the seat back frame. Important: Note the position and length of all the bolts removed. This will assist with reassembly. 6. Remove the bolts that retain the seat back hinge to the seat back frame. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 7. Remove the seat back hinge from the seat back frame. Installation Procedure 1. Install the seat back hinge to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts retaining the seat back hinge to the seat back frame. Install the bolts in the locations noted during disassembly. Tighten the bolts retaining the seat back hinge to the seat back frame to 30 N.m (22 lb ft). 3. Install the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 4. Install the bolts that retain the seat back hinge to the seat cushion frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9127 Install the bolts in the locations from which they were removed, as noted during disassembly. Tighten the bolts that retain the seat back hinge to the seat cushion frame to 30 N.m (22 lb ft). 5. Install the seat cushion J-hook to the seat cushion frame as follows: 1. Install the J-hook that retains the seat cover to the carpet on the back of the seat on the side of the seat containing the recliner. 2. Install the J-hook to the seat frame on the side of the seat containing the seat back hinge. 3. Install the J-hook to the rear of the seat back. 6. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9128 Seat Back: Service and Repair Seat Back Hinge Replacement - Front (YC7) Seat Back Hinge Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the seat riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the armrest from the same side of the seat as the hinge. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 3. Remove the J-hooks that retains the carpet on the seat back cushion and to the corners of the seat cushion cover. 4. Remove the seat cover and pad. Refer toSeat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . Important: Note the position and length of all the bolts removed. This will assist with reassembly. 5. Remove the bolts that retain the seat back hinges to the seat cushion and the seat back frame. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 6. Remove the seat back hinges from the seat frame. Installation Procedure 1. Install the seat back hinges to the seat frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the seat back hinges to the seat back frame and to the seat cushion frame. Tighten the bolts that retain the seat back hinges to the seat back frame and the seat cushion frame to 30 N.m (22 lb ft). 3. Install the bolts in the locations noted during disassembly. 4. Install seat cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 5. Install the J-hooks that retain the carpet to the seat back and to seat cushion frame and to the corners of the seat cushion cover. 6. Install the armrest. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 7. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9129 Seat Back: Service and Repair Seat Back Recliner Replacement - Front (YC5, YC6) Seat Back Recliner Replacement - Front (YC5, YC6) Removal Procedure 1. Remove the bucket seat from the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the screw that retain the recliner handle to the recliner. 3. Remove the following seat cover J-hooks from the seat cushion frame: * The J-hook at the rear of the seat. * The J-hook on the recliner side of the seat. * The J-hook on the recliner side of the seat that retains the seat back cover and to the carpet to the seat back. Important: When removing the recliner retaining bolts, note the position and length of the bolts. This will assist with reassembly. 4. Remove the bolts that retain the recliner to the seat cushion frame. 5. Remove the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 6. Lift the seat back cover and pad above the bolts that retain the recliner to the seat back frame. Important: When removing the bolts, note the position and length of the bolts. This will assist with reassembly. 7. Remove the bolts that retain the recliner. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 8. Remove the recliner from the seat back frame. Installation Procedure 1. Install the recliner to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the recliner to the seat back frame. Install the bolts in the locations noted during removal. Tighten the bolts that retain the recliner to the seat back frame to 30 N.m (22 lb ft). 3. Refit the seat back cover and pad over the bolts that retain the recliner to the seat back frame. 4. Install the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9130 5. Install the bolts that retain the recliner to the seat cushion frame. Install the bolts in the positions from which they were removed, as noted during disassembly. Tighten the bolts that retain the recliner to the seat cushion frame to 30 N.m (22 lb ft). 6. Install the seat cover J-hooks to the seat cushion frame as follows: 1. Install the J-hook that retain the seat cover to the carpet on the back of the recliner side of the seat. 2. Install the J-hook to the seat frame on the recliner side of the seat. 3. Install the J-hook at the rear of the seat. 7. Install the screw that retains the recliner handle to the recliner. Tighten the screw that retains the recliner handle to the recliner to 2 N.m (18 lb in). 8. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9131 Seat Back: Service and Repair Seat Back Frame Replacement - Front Seat Back Frame Replacement - Front Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat back cover and pad . Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 3. Remove the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 4. Remove the bolts from the seat back hinges on the right and left side. 5. Remove the seat back frame. Installation Procedure 1. Install the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts to the seat back hinges on the right and left side. Tighten the bolts to the seat back hinges on the right and left side to 30 N.m (22 lb in). 3. Install the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9132 4. Install the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 5. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Hinge Replacement - Front (YC5 and YC6) Seat Back Hinge Replacement - Front (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the seat riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat cover J-hook from the seat cushion frame: 1. Remove the J-hook at the rear of the seat. 2. Remove the J-hook on the side of the seat containing the seat back hinge. 3. Remove the J-hook that retains the cover to the carpet on the back of the seat on the side of the seat containing the seat back hinge. Important: Note the position and length of all the bolts removed. This will assist with reassembly. 3. Remove the bolts that retain the seat back hinge to the seat cushion frame. 4. Remove the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 5. Lift the seat back cover and pad above the bolts that retain the seat back hinge to the seat back frame. Important: Note the position and length of all the bolts removed. This will assist with reassembly. 6. Remove the bolts that retain the seat back hinge to the seat back frame. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 7. Remove the seat back hinge from the seat back frame. Installation Procedure 1. Install the seat back hinge to the seat back frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9133 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts retaining the seat back hinge to the seat back frame. Install the bolts in the locations noted during disassembly. Tighten the bolts retaining the seat back hinge to the seat back frame to 30 N.m (22 lb ft). 3. Install the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 4. Install the bolts that retain the seat back hinge to the seat cushion frame. Install the bolts in the locations from which they were removed, as noted during disassembly. Tighten the bolts that retain the seat back hinge to the seat cushion frame to 30 N.m (22 lb ft). 5. Install the seat cushion J-hook to the seat cushion frame as follows: 1. Install the J-hook that retains the seat cover to the carpet on the back of the seat on the side of the seat containing the recliner. 2. Install the J-hook to the seat frame on the side of the seat containing the seat back hinge. 3. Install the J-hook to the rear of the seat back. 6. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Hinge Replacement - Front (YC7) Seat Back Hinge Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the seat riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the armrest from the same side of the seat as the hinge. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 3. Remove the J-hooks that retains the carpet on the seat back cushion and to the corners of the seat cushion cover. 4. Remove the seat cover and pad. Refer toSeat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . Important: Note the position and length of all the bolts removed. This will assist with reassembly. 5. Remove the bolts that retain the seat back hinges to the seat cushion and the seat back frame. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 6. Remove the seat back hinges from the seat frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9134 Installation Procedure 1. Install the seat back hinges to the seat frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the seat back hinges to the seat back frame and to the seat cushion frame. Tighten the bolts that retain the seat back hinges to the seat back frame and the seat cushion frame to 30 N.m (22 lb ft). 3. Install the bolts in the locations noted during disassembly. 4. Install seat cover and pad. Refer to Seat Back Cover and Pad Replacement (YC5 and YC6) (See: Seat Back Cover and Pad Replacement (YC5 and YC6))Seat Back Cover and Pad Replacement (YC7) (See: Seat Back Cover and Pad Replacement (YC7)) . 5. Install the J-hooks that retain the carpet to the seat back and to seat cushion frame and to the corners of the seat cushion cover. 6. Install the armrest. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 7. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Recliner Replacement - Front (YC5, YC6) Seat Back Recliner Replacement - Front (YC5, YC6) Removal Procedure 1. Remove the bucket seat from the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the screw that retain the recliner handle to the recliner. 3. Remove the following seat cover J-hooks from the seat cushion frame: * The J-hook at the rear of the seat. * The J-hook on the recliner side of the seat. * The J-hook on the recliner side of the seat that retains the seat back cover and to the carpet to the seat back. Important: When removing the recliner retaining bolts, note the position and length of the bolts. This will assist with reassembly. 4. Remove the bolts that retain the recliner to the seat cushion frame. 5. Remove the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 6. Lift the seat back cover and pad above the bolts that retain the recliner to the seat back frame. Important: When removing the bolts, note the position and length of the bolts. This will assist with reassembly. 7. Remove the bolts that retain the recliner. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9135 the seat back hinge or the lumbar support cable. 8. Remove the recliner from the seat back frame. Installation Procedure 1. Install the recliner to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the recliner to the seat back frame. Install the bolts in the locations noted during removal. Tighten the bolts that retain the recliner to the seat back frame to 30 N.m (22 lb ft). 3. Refit the seat back cover and pad over the bolts that retain the recliner to the seat back frame. 4. Install the armrests, if equipped. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 5. Install the bolts that retain the recliner to the seat cushion frame. Install the bolts in the positions from which they were removed, as noted during disassembly. Tighten the bolts that retain the recliner to the seat cushion frame to 30 N.m (22 lb ft). 6. Install the seat cover J-hooks to the seat cushion frame as follows: 1. Install the J-hook that retain the seat cover to the carpet on the back of the recliner side of the seat. 2. Install the J-hook to the seat frame on the recliner side of the seat. 3. Install the J-hook at the rear of the seat. 7. Install the screw that retains the recliner handle to the recliner. Tighten the screw that retains the recliner handle to the recliner to 2 N.m (18 lb in). 8. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Recliner Replacement - Front (YC7) Seat Back Recliner Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the armrest from the recliner side of the seat. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 3. Remove the J-hooks that retain the carpet on the back of the seat cushion to the corners of the seat cushion trim cover. 4. Remove the screw that retains the seat back recliner handle to the recliner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9136 Important: When removing the bolts that retain the seat back recliner, note the position and length of the bolts. This will assist with reassembly. 5. Remove the bolts that retain the recliner to the seat back and seat cushion frames. Important: Handle the seat carefully when just one side of the seat back is attached to the seat cushion. Improper handling may damage the seat back hinge or the lumbar support cable. 6. Remove the seat back recliner from the seat frame. Installation Procedure 1. Install the seat back recliner to the seat frame. 2. Install the seat back bolts that retain the recliner to the seat back and the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the seat back bolts in the locations noted during disassembly. Tighten the seat back bolts that retain the recliner to the seat back and the seat cushion frames to 30 N.m (22 lb ft). 4. Install the screw that retains the seat back recliner handle to the seat back recliner. Tighten the screw that retains the seat back recliner handle to the seat back recliner to 2 N.m (18 lb in). 5. Install the J-hooks that retain the carpet to the seat back and to seat cushion frame and to the corners of the seat cushion cover. 6. Install the armrest to the seat back recliner side of the seat. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 7. Install the bucket seat to the riser. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the headrests. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 3. Remove the rear seat armrests, if equipped. Refer to Armrest Replacement - Rear Seat (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC7))Armrest Replacement - Rear Seat (YC5 and YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC5 and YC6)) . 4. Remove the right and left seat back hinge. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back Hinge Trim Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9137 Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back Hinge Trim Replacement - Rear Left) . 5. Remove the headrest bushings. 6. Unzip the seat back cover. 7. Remove the seat back cover and pad from the seat back frame. Important: Note the locations of the hog rings. This will assist with reassembly. 8. Remove the hog rings that retain the seat back cover to the pad. 9. Remove the seat back cover from the pad. Installation Procedure 1. Install the seat back cover to the pad. Important: Note install the hog rings in the locations noted during disassembly. 2. Install the hog rings in order to retain the seat back cover to the pad. 3. Install the seat back cover and pad to the seat back frame. 4. Zip the seat back cover closed. 5. Press the headrest bushings into place. 6. Install the right and left seat back hinge. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back Hinge Trim Replacement - Rear Left) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9138 7. Install the rear seat armrests, if equipped. Refer to Armrest Replacement - Rear Seat (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC7))Armrest Replacement - Rear Seat (YC5 and YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC5 and YC6)) . 8. Install the headrests. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 9. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Cover and Pad Replacement - Rear (YC7) Seat Back Cover and Pad Replacement - Rear (YC7) Removal Procedure 1. Remove the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the rear seat headrest. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 3. Remove the rear seat armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 4. Remove the J-hook along the bottom edge of the seat back. 5. Separate the J-hook fasteners that retain the sea back cover to the pad along the seat back break line. 6. Remove the seat back cover and pad from the seat back. 7. Remove the pad from the seat back frame. Installation Procedure 1. Install the pad to the seat back frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9139 Important: For the best finished appearance, proceed as follows when attaching the seat back cover to the pad: 2. Install the seat back cover to the seat back. 1. Center the seat back cover on the pad. 2. Starting at the top and working down the sides, apply pressure along the break line in order to help attach the seat back cover to the J-hook to the frame and attach the hook and loop. 3. Install the seat back to the frame and attach. 4. Install the armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 5. Install the headrests. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 6. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Frame Replacement - Rear (YC7) Seat Back Frame Replacement - Rear (YC7) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) (See: Seat Back Cover and Pad Replacement - Rear (YC5 and YC6))Seat Back Cover and Pad Replacement - Rear (YC7) (See: Seat Back Cover and Pad Replacement - Rear (YC7)) . Important: Note the position and the length of the bolts removed. This will assist with reassembly. 3. Remove the right and left bolts that retain the seat back frame to the seat back hinges. 4. Remove the seat back frame. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9140 1. Install the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the seat back frame to the seat back hinges in the locations noted during disassembly. Tighten the bolts that retain the seat back frame to the seat back hinges to 30 N.m (22 lb ft). 3. Install the seat back cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion/Service and Repair/Seat Cushion Cover and Pad Replacement - Rear) . 4. Install the bench seat in the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Frame Replacement - Rear (YC5 and YC6) Seat Back Frame Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) (See: Seat Back Cover and Pad Replacement - Rear (YC5 and YC6))Seat Back Cover and Pad Replacement - Rear (YC7) (See: Seat Back Cover and Pad Replacement - Rear (YC7)) . 3. Remove the headrest bushing. Refer to Bucket Seat Head Restraint Bushing Replacement (See: Head Rest/Service and Repair/Bucket Seat Head Restraint Bushing Replacement) . 4. Remove the rear seat latch release cable. Refer to Seat Back Latch Release Cable Replacement - Rear (See: Seat Back Latch Release Cable Replacement - Rear) . 5. Remove the right and left seat back frame hinge bolts. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9141 6. Remove the seat back frame. Installation Procedure 1. Install the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the right and left seat back frame hinge bolts. Tighten the right and left seat back frame hinge bolts to 30 N.m (22 lb ft). 3. Install the rear seat latch release cable. Refer to Seat Back Latch Release Cable Replacement Rear (See: Seat Back Latch Release Cable Replacement - Rear) . 4. Install the headrest bushing. Refer to Bucket Seat Head Restraint Bushing Replacement (See: Head Rest/Service and Repair/Bucket Seat Head Restraint Bushing Replacement) 5. Install the seat back cover and pad. Refer to Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) (See: Seat Back Cover and Pad Replacement - Rear (YC5 and YC6))Seat Back Cover and Pad Replacement - Rear (YC7) (See: Seat Back Cover and Pad Replacement - Rear (YC7)) . 6. Install the bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Hinge Replacement - Rear (YC5 and YC6) Seat Back Hinge Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the right and left sides of the seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back Hinge Trim Replacement - Rear Left) . Important: Note the position and the length of the bolts removed. This will assist with reassembly. 3. Remove the bolts that retain the seat back hinge to the seat back frame and the seat cushion frame. 4. Remove the latch release cable from the seat back hinge. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9142 5. Remove the seat back hinge from the seat cushion frame. Installation Procedure 1. Install the seat back hinge to the seat cushion frame. 2. Install the latch release cable to the seat back hinge. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the right and left bolts that retain the seat back hinge to the seat back frame and the seat cushion frame in the locations noted during disassembly. Tighten the right and left bolts retaining the seat back hinge to the seat back frame and the seat cushion frame to 30 N.m (22 lb ft). 4. Install the right and left sides of the rear seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back Hinge Trim Replacement - Rear Left) . 5. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Hinge Replacement - Rear (YC7) Seat Back Hinge Replacement - Rear (YC7) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the carpet covering the center of the seat cushion frame along the rear edge of the seat , near the inner hinge. Important: Note the position of the hog rings for reassembly. 3. Remove the hog rings that retain the carpet to the frame. Important: Note the position and length of the bolts removed. This will assist with reassembly. 4. Remove the bolt that retain the inner seat back hinge to the seat cushion frame. 5. Remove the hook and loop fastener at the rear corner of the seat cushion cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9143 6. Remove the hog rings that retain the seat back cover to the seat cushion frame along the side of the seat cover. * Remove only as many hog rings as necessary to gain access to the seat back hinge mounting bolts on the seat cushion frame. * Note the locations of the hog rings removed. This will assist with reassembly. Important: Note the position and length of the bolts removed. This will assist with reassembly. 7. Remove the bolts that retain the seat back hinge to the seat cushion frame. 8. Remove the seat back and the seat back hinges from the seat back frame. 9. Remove the armrests. Refer to Armrest Replacement - Rear Seat (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC7))Armrest Replacement - Rear Seat (YC5 and YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement - Rear Seat (YC5 and YC6)) . 10. Remove the bolts that retain the seat back seat back hinges to the seat back frame. 11. Remove the seat back hinges from the seat back frame. Installation Procedure 1. Install the seat back hinges to the seat back frame. Notice: Refer to Fastener Notice in Cautions in Notices. 2. Install the bolts that retain the seat back hinges to the seat back frame in the locations noted during disassembly. Tighten the bolts that retain the seat back hinges to the seat back frame to 30 N.m (22 lb ft). 3. Install the armrests. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9144 4. Install the seat back and seat back hinges to the seat. 5. Install the bolts that retain the seat back hinge to the seat cushion frame in the locations noted during disassembly. Tighten the bolts that retain the seat back hinge to the seat cushion frame to 30 N.m (22 lb ft). 6. Install the hog rings that retain the seat cushion cover and pad to the seat cushion frame along the side of the seat cushion in the locations noted during disassembly. 7. Connect the hook and loop fastener at the rear corner of the seat cushion cover. 8. Install the bolt that retains the inner seat back hinge to the seat cushion frame. Tighten the bolt that retain the inner seat back hinge to the seat cushion frame to 30 N.m (22 lb ft). 9. Install the hog rings in the locations noted during disassembly. 10. Install the carpet covering the center of the seat cushion frame along the rear edge of the seat, near the inner hinge. 11. Install the rear bench seat to the vehicle. Refer to Seat Replacement Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Hinge Trim Replacement - Rear Left Seat Back Hinge Trim Replacement - Rear Left Removal Procedure 1. Remove the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the screw retaining the lower hinge cover. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9145 3. Pry off the lower hinge cover. 4. Pry off the upper hinge cover. Installation Procedure 1. Install the upper seat back hinge cover as follows: 1. Align the fasteners with the hinge. 2. Press the lower seat back hinge cover into place. 2. Install the lower seat back hinge cover as follows: 1. Align the fasteners with the hinge. 2. Press the upper seat back hinge cover into place. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the lower seat back hinge cover retaining screw. Tighten the lower seat back hinge cover retaining screw to 2 N.m (18 lb in). 4. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Recliner Handle Replacement - Front Seat Back Recliner Handle Replacement - Front Removal Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9146 1. Remove the screw that retains the seat back recliner lever to the seat back recliner. 2. Remove the seat back recliner lever from the seat back recliner. Installation Procedure 1. Install the seat back recliner lever to the seat back recliner. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screw that retains the seat back recliner lever. Tighten the screw that retain the seat back recliner lever to 2 N.m (18 lb in). Seat Back Cover and Pad Replacement (YC5 and YC6) Seat Back Cover and Pad Replacement (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 3. Disconnect the J-hook fasteners at the bottom corners of the seat back. 4. Remove the seat back cover and pad from the seat back frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9147 Important: Note the locations of the hog rings. This will assist with reassembly. 5. Remove the hog rings that retain the seat back cover to the pad. 6. Remove the seat back cover from the pad. Installation Procedure 1. Install the seat back cover to the pad. Important: Install the hog rings that retain the seat back cover to the pad in the locations noted during disassembly. 2. Install the hog rings to seat back cover to the pad. 3. Install the seat back and pad to the seat back frame. 4. Connect the J-hook fasteners at the bottom corner of the seat back. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9148 5. Install the armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 6. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Cover and Pad Replacement (YC7) Seat Back Cover and Pad Replacement (YC7) Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the headrest. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 3. Remove the armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 4. Disconnect the hook-and-loop fasteners that retain the seat cushion cover to the pad along the seat back break line. 5. Remove the seat back cover and pad from the seat back. Installation Procedure Important: For the best finished appearance when attaching the seat back cover to the pad, proceed as follows: 1. Install the seat back pad to the seat back frame. 2. Center the seat back cover on the pad. 3. Starting at the top and working down the sides, apply pressure along the break line. This helps attach the seat back cover to the J-hook fasteners. 4. Reset the hook-and-loop fasteners that retain the seat back cushion to the pad. 5. Install the armrests. Refer to Armrest Replacement (YC6) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC6))Armrest Replacement (YC7) (See: Interior Moulding / Trim/Arm Rest/Service and Repair/Armrest Replacement (YC7)) . 6. Install the headrest. Refer to Head Restraint Replacement (YC6) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC6))Head Restraint Replacement (YC7) (See: Head Rest/Service and Repair/Head Restraint Replacement (YC7)) . 7. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Back Latch Release Cable Replacement - Rear Seat Back Latch Release Cable Replacement - Rear Removal Procedure 1. Remove the bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9149 2. Unzip the seat back cover. 3. Remove the seat back cushion cover and pad. Refer to Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) (See: Seat Back Cover and Pad Replacement - Rear (YC5 and YC6))Seat Back Cover and Pad Replacement - Rear (YC7) (See: Seat Back Cover and Pad Replacement - Rear (YC7)) . 4. Remove the seat back cable end from the seat back latch. 5. Remove the seat back latch release cable from the clips that retains the cable to the seat back frame. 6. Remove the seat back latch release cable from the seat back frame. Installation Procedure 1. Install the seat back latch release cable to the seat back frame. 2. Install the seat back latch release cable to the clips that retain the cable to the seat back frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9150 3. Install the seat back cable end to the seat back latch. 4. Install the seat back cushion cover and pad. Refer to Seat Back Cover and Pad Replacement - Rear (YC5 and YC6) (See: Seat Back Cover and Pad Replacement - Rear (YC5 and YC6))Seat Back Cover and Pad Replacement - Rear (YC7) (See: Seat Back Cover and Pad Replacement - Rear (YC7)) . 5. Zip the seat back cover. 6. Install the bench seat to the vehicle. Refer to Seat Replacement Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Back Hinge Trim Replacement - Rear Right (YC6) Seat Back Hinge Trim Replacement - Rear Right (YC6) Removal Procedure 1. Remove the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the screw that retains the lower seat back hinge cover . 3. Pry off the lower seat back hinge cover. 4. Remove the latch lever escutcheon as follows: 1. Unfasten the J-hook fastener along the inner edge of the escutcheon. 2. Lift the inner edge of the escutcheon. 3. Pivot the escutcheon in order to clear the latch lever and the retaining tabs at the seat back hinge upper cover. 5. Pry off the upper seat back hinge. Installation Procedure 1. Install the upper seat back hinge cover: 1. Align the seat back hinge cover fasteners with the hinge. 2. Press the seat back hinge cover into place. 2. Install the latch lever escutcheon: 1. Pivot the escutcheon so that the escutcheon retaining tabs engage the slots on the upper hinge cover and clear the latch lever. 2. Attach the J-hook fasteners at the escutcheon's inner edge to the carpet on the back of the seat back trim cover. 3. Install the lower hinge cover: 1. Align the seat back hinge cover fasteners with the hinge. 2. Press the seat back hinge cover into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 9151 Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the screw that retains the lower seat back hinge cover . Tighten the lower seat back hinge cover retaining screw to 2 N.m (18 lb in). 5. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9156 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9157 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9158 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9159 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9160 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 9161 Seat Cover: Technical Service Bulletins Interior - Napped Seat Fabric Repair Bulletin No.: 04-08-50-011A Date: May 04, 2006 INFORMATION Subject: Repairing Napped Seat Fabric Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 1999-2006 Chevrolet Silverado 2000-2007 Chevrolet Suburban, Tahoe 2002-2005 Chevrolet Astro 2002-2006 Chevrolet Monte Carlo 2002-2007 Chevrolet Avalanche 2002-2005 GMC Safari 2007 GMC Yukon, Yukon XL 2002-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Prix Supercede: This bulletin is being revised to add model years and models. Please discard Corporate Bulletin Number 04-08-50-011 (Section 08 - Body & Accessories). This bulletin is being issued to advise technicians/dealers on the proper repair required when a customer brings in a trimmed seat with the appearance of being worn, having a bald spot and/or being discolored. The seats in the later vehicles are trimmed with a cloth that has a napped fabric. Under some circumstances, the nap may become crushed down by normal use, giving the appearance of being worn out. If the base material is NOT visible, use a small brass (NOT STEEL) wire brush to carefully fluff and raise the nap. The wire brush (fine bristle brass) is available at most hardware and home stores. If the base material is visible, replace the trim cover. The Astro/Safari van will also have this material on the door trim. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) Seat Cushion: Service and Repair Seat Cushion Cover Replacement - Front (YC5 and YC6) Seat Cushion Cover Replacement - Front (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the screw from the recliner lever handle if equipped. 3. Remove the lever from the recliner if equipped. 4. Remove the lumbar knob and clip if equipped. 5. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. Important: Note the positions of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the seat cushion frame. 7. Remove the seat cushion cover and pad from the seat cushion frame. 8. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. 2. Install the seat cushion cover and the pad to the seat cushion frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9166 3. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 4. Install the J-hook that retain the seat cushion cover to the seat cushion frame. 5. Install the lumbar knob and clip if equipped. 6. Install the lever to the recliner if equipped. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the screw to the recliner lever handle if equipped. Tighten the screw to the recliner lever handle to 2 N.m (18 lb in). 8. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9167 Seat Cushion: Service and Repair Seat Cushion Cover Replacement - Front (YC7) Seat Cushion Cover Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Important: Note the position and length of the bolts you remove. This will assist with reassembly. 2. Remove the bolts that retain the seat back hinges to the seat cushion frame. Refer to Seat Back Frame Replacement - Front (See: Seat Back/Service and Repair/Seat Back Frame Replacement - Front) . 3. Remove the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 4. Remove the hog rings that retain the seat cushion cover and pad to the seat cushion frame. 5. Remove the seat cushion cover and pad from the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the pad. 7. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. 2. Install the hog rings that retain the seat cushion cover to the pad in the locations noted during disassembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9168 3. Install the seat cushion cover and the pad to the seat cushion frame. 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 5. Install the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. Tighten the bolts to 30 N.m (22 lb ft). 7. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9169 Seat Cushion: Service and Repair Seat Cushion Frame Replacement Seat Cushion Frame Replacement Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 3. Remove Lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 4. Remove the seat back hinge bolts from the right side of the seat frame. 5. Remove the seat back hinge bolts from the left side of the seat frame. 6. Remove the seat cushion frame from the seat back frame. Installation Procedure 1. Install the seat cushion frame to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the left side of the seat frame. Tighten the seat back hinge bolts to the left side of the seat frame to 30 N.m (22 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9170 3. Install the bolts to the right side of the seat frame. Tighten the seat back hinge bolts to the right side of the seat frame to 30 N.m (22 lb ft). 4. Install the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 5. Install the seat cushion cover and pad . Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 6. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9171 Seat Cushion: Service and Repair Seat Cushion Frame Replacement - Rear (YC5 and YC6) Seat Cushion Frame Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . 3. Remove the seat back hinge bolts from the right and left sides of the cushion frame. 4. Remove the seat cushion frame. Installation Procedure 1. Install the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the right and left sides of the seat cushion frame. Tighten the seat back hinge bolts to the right and left sides of the seat cushion frame 30 N.m (22 lb ft). 3. Install the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement Rear (See: Seat Cushion Cover and Pad Replacement Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9172 - Rear) . 4. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9173 Seat Cushion: Service and Repair Seat Cushion Cover Replacement - Front (YC5 and YC6) Seat Cushion Cover Replacement - Front (YC5 and YC6) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the screw from the recliner lever handle if equipped. 3. Remove the lever from the recliner if equipped. 4. Remove the lumbar knob and clip if equipped. 5. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. Important: Note the positions of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the seat cushion frame. 7. Remove the seat cushion cover and pad from the seat cushion frame. 8. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9174 2. Install the seat cushion cover and the pad to the seat cushion frame. 3. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 4. Install the J-hook that retain the seat cushion cover to the seat cushion frame. 5. Install the lumbar knob and clip if equipped. 6. Install the lever to the recliner if equipped. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the screw to the recliner lever handle if equipped. Tighten the screw to the recliner lever handle to 2 N.m (18 lb in). 8. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Cover Replacement - Front (YC7) Seat Cushion Cover Replacement - Front (YC7) Removal Procedure 1. Remove the bucket seat from the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Important: Note the position and length of the bolts you remove. This will assist with reassembly. 2. Remove the bolts that retain the seat back hinges to the seat cushion frame. Refer to Seat Back Frame Replacement - Front (See: Seat Back/Service and Repair/Seat Back Frame Replacement - Front) . 3. Remove the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 4. Remove the hog rings that retain the seat cushion cover and pad to the seat cushion frame. 5. Remove the seat cushion cover and pad from the seat cushion frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9175 Important: Note the locations of the hog rings for reassembly. 6. Remove the hog rings that retain the seat cushion cover to the pad. 7. Remove the seat cushion cover from the pad. Installation Procedure 1. Install the seat cushion cover to the pad. 2. Install the hog rings that retain the seat cushion cover to the pad in the locations noted during disassembly. 3. Install the seat cushion cover and the pad to the seat cushion frame. 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame in the locations noted during disassembly. 5. Install the J-hooks that retain the seat cushion cover and pad to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. Tighten the bolts to 30 N.m (22 lb ft). 7. Install the bucket seat to the seat risers. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Frame Replacement Seat Cushion Frame Replacement Removal Procedure 1. Remove the bucket seat from the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 3. Remove Lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9176 4. Remove the seat back hinge bolts from the right side of the seat frame. 5. Remove the seat back hinge bolts from the left side of the seat frame. 6. Remove the seat cushion frame from the seat back frame. Installation Procedure 1. Install the seat cushion frame to the seat back frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the left side of the seat frame. Tighten the seat back hinge bolts to the left side of the seat frame to 30 N.m (22 lb ft). 3. Install the bolts to the right side of the seat frame. Tighten the seat back hinge bolts to the right side of the seat frame to 30 N.m (22 lb ft). 4. Install the lumbar support cable. Refer to Lumbar Support Cable Replacement (See: Service and Repair/Lumbar Support Cable Replacement) . 5. Install the seat cushion cover and pad . Refer to Seat Cushion Cover Replacement - Front (YC5 and YC6) (See: Seat Cushion Cover Replacement - Front (YC5 and YC6))Seat Cushion Cover Replacement - Front (YC7) (See: Seat Cushion Cover Replacement - Front (YC7)) . 6. Install the bucket seat in the vehicle. Refer to Seat Replacement - Bucket (See: Service and Repair/Seat Replacement - Bucket) . Seat Cushion Frame Replacement - Rear (YC5 and YC6) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9177 Seat Cushion Frame Replacement - Rear (YC5 and YC6) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . 3. Remove the seat back hinge bolts from the right and left sides of the cushion frame. 4. Remove the seat cushion frame. Installation Procedure 1. Install the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the seat back hinge bolts to the right and left sides of the seat cushion frame. Tighten the seat back hinge bolts to the right and left sides of the seat cushion frame 30 N.m (22 lb ft). 3. Install the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . 4. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9178 Seat Cushion Frame Replacement - Rear (YC7) Seat Cushion Frame Replacement - Rear (YC7) Removal Procedure 1. Remove the rear bench seat from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the seat cushion cover and pad. Refer to Seat Cushion Cover and Pad Replacement - Rear (See: Seat Cushion Cover and Pad Replacement - Rear) . Important: Note the position and length of the bolts removed. This will assist with reassembly. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. Important: Note the position and length of the bolts removed. This will assist with reassembly. 4. Remove the bolts retaining the console to the seat cushion frame. Refer to Center Console Replacement - Rear Seat (See: Interior Moulding / Trim/Console/Service and Repair/Center Console Replacement - Rear Seat) . 5. Remove the seat cushion frame. Installation Procedure 1. Install the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the console to the seat cushion frame in the locations noted during disassembly. Refer to Center Console Replacement Rear Seat (See: Interior Moulding / Trim/Console/Service and Repair/Center Console Replacement - Rear Seat) . Tighten the bolts that retain the console to the seat cushion frame to 30 N.m (22 lb ft). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9179 3. Install the bolts that retain the seat back hinges to the seat cushion frame in the locations noted during disassembly. Tighten the bolts that retain the seat back hinges to the bench seat cushion frame to 30 N.m (22 lb ft). 4. Install the seat cushion cover and pad. 5. Install the rear bench seat to the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Seat Cushion Cover and Pad Replacement - Rear Seat Cushion Cover and Pad Replacement - Rear Removal Procedure 1. Remove the bench seat and risers from the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . 2. Remove the right and left sides of the seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Left) . Important: Note the position and length of the bolts you remove. This will assist with reassembly. 3. Remove the bolts retaining the seat back hinges to the seat cushion frame. 4. Remove the J-hooks that retain the seat cushion cover to the seat cushion frame. Important: Note the locations of the hog rings for reassembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9180 5. Remove the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. 6. Remove the seat back cushion cover and pad from the seat cushion frame. Important: Note the locations of the hog rings for reassembly. 7. Remove the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. 8. Remove the seat cushion cover from the seat cushion pad. Installation Procedure 1. Install the seat cushion cover to the seat cushion pad. 2. Install the hog rings that retain the seat cushion cover to the seat cushion pad located under the seat cushion cover. 3. Install the seat back cushion cover and pad to the seat cushion frame. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat Cushion Cover Replacement - Front (YC5 and YC6) > Page 9181 4. Install the hog rings that retain the seat cushion cover to the seat cushion frame located at the rear edge of the seat frame. 5. Install the J-hooks that retain the seat cushion cover to the seat cushion frame. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the bolts that retain the seat back hinges to the seat cushion frame. Tighten the bolts that retain the seat back hinges to the seat cushion frame to 30 N.m (22 lb ft). 7. Install the right and left sides of the seat back hinge trim. Refer to Seat Back Hinge Trim Replacement - Rear Right (YC6) (See: Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Right (YC6)) and Seat Back Hinge Trim Replacement - Rear Left (See: Seat Back/Service and Repair/Seat Back Hinge Trim Replacement - Rear Left) . 8. Install the bench seat and risers in the vehicle. Refer to Seat Replacement - Rear Bench (See: Service and Repair/Seat Replacement - Rear Bench) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver Door Lock Switch - Front Passenger Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9186 Power Door Lock Switch: Service and Repair REMOVAL PROCEDURE 1. Remove the armrest screws and the armrest YC5. 2. Remove the window handle, if equipped. 3. Pull out on the escutcheon in order to remove the lock lever escutcheon. Start with the front edge of the escutcheon. 4. Remove the upper corner trim using the following method: 4.1. Pull the upper corner trim at the top edge. 4.2. Pivot the upper corner trim down in order to clear the tab at the trim panel, YC6 and YC7. 5. Remove the caps that cover the screws for the assist handle. 6. Remove the screws that retain the assist handle to the door. 7. Remove the screw at the front edge of the accessory switch mount plate. 8. Remove the plate from the trim panel. 9. Disconnect the electrical connectors from the switches on the plate, as needed. INSTALLATION PROCEDURE 1. Connect the electrical connectors to the switches on the accessory switch mounting plate, as needed. 2. Install the plate to the trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw at the front edge of the accessory switch mount plate. Tighten Tighten the screws at the front edge of the accessory switch mount plate to 5 N.m (44 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9187 4. Install the assist handle and screws to the door. Tighten Tighten the assist handle screws to 5 N.m (44 lb in). 5. Install the caps that cover the screws on the assist handle. 6. Insert the tab in the slot on the door trim panel. Seat the fastener into the door at the top, YC6 and YC7 in order to install the upper corner trim. 7. Snap the lock lever escutcheon into place in order to install the lock lever escutcheon. Start at the rear edge of the escutcheon. 8. Install the window handle, if equipped. 9. Install the armrest and armrest screws, YC5. Tighten Tighten the armrest screws to 5 N.m (44 lb in). For a description of the RPO Code(s) shown in this article or any of the images therein, refer to the RPO Code List found at Vehicle/Application See: Application and ID Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9191 Seat Adjuster Switch - Driver Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9192 Power Seat Switch: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9193 Power Seat Switch: Service and Repair Seat Switch Replacement - Power Removal Procedure 1. Remove the screws that retain the power seat switch to the seat. 2. Disconnect the electrical connector from the power seat switch. 3. Remove the power seat switch. Installation Procedure 1. Connect the power seat switch electrical connector. 2. Install the power seat switch. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 9194 Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws that retain the power seat switch to the seat. Tighten the power seat switch retaining screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair Air Dam: Service and Repair Air Intake Baffle Replacement - Radiator Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Unhook the power steering cooler lines (2) from the air baffle. 3. Remove the push-in retainers (4) on the right and left sides of the air baffle. 4. Remove the screws (3) that attaches the air baffle to the radiator support. 5. Pull the air baffle rearward in order to release the air baffle from the radiator support. 6. Remove the air baffle (1). Installation Procedure 1. Position the air baffle (1) into the radiator support. 2. Align the tabs of the air baffle to the radiator support before installing the screws. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the screws (3) that attach the air baffle to the radiator support. Tighten the screws that attaches the air baffle to the radiator support to 2 N.m (18 lb in). 4. Remove the push clips (4) on the right and left sides of the air baffle. 5. Hook the power steering cooler lines (2) to the air baffle. 6. Lower the vehicle. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside Tailgate Release Handle: Service and Repair Handle and Lock Cylinder - Rear Door Outside Handle and Lock Cylinder - Rear Door Outside New lock cylinders are available as replacement parts. If the door lock cylinders require replacement for any reason, apply a coating of lubricant. Use GM P/N 12346241 or the equivalent, inside the lock case and the cylinder keyway prior to assembling and installing the cylinder. Refer toBinding Lock Cylinders (See: Locks/Door Locks/Service and Repair/Procedures) in Doors in order to repair a binding lock cylinder. Refer to Key and Lock Cylinder Coding (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Key & Lock Cylinder Coding) in General Information in order to code a new lock cylinder. Removal Procedure 1. Remove the trim panel and the access cover. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Remove the Water Deflector. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 3. Use the following procedure in order to remove the control rod from the outside handle: 1. Pry the clip anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod (1) and the clip away from the lever. 4. Remove the outside handle nuts. 5. Remove the outside handle. 6. Disconnect the license lamp wiring. 7. Remove the license plate housing bolts. 8. Remove the license plate housing. 9. Remove the door lock shield. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9204 10. Use the following procedure in order to remove the control rod from the lock cylinder (3): 1. Pry the clip anchor out of the hole. 2. Push the clip away from the lever. 3. Pull the rod and the clip away from the lever. 11. Remove the lock cylinder retainer (1). 12. Remove the lock cylinder. Installation Procedure 1. Install the clip to the lock cylinder (3). 2. Install the lock cylinder to the door. 3. Install the lock cylinder retainer (1). 4. Install the control rod to the lock cylinder through the clip. 5. Install the door lock shield. 6. Install the license plate housing. Notice: Refer to Fastener Notice in Cautions and Notices. 7. Install the license plate housing bolts. Tighten the bolts to 4 N.m (35 lb in). 8. Install the license lamp bolts. Tighten the bolts to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9205 9. Install the clip to the outside handle. 10. Install the outside handle to the door. 11. Install the outside handle nuts. Tighten the nuts to 7 N.m (62 lb in). 12. Install the control rod (1) to the outside handle through the clip. 13. Install the water deflector. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 14. Install the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9206 Tailgate Release Handle: Service and Repair Handle Replacement - Lift Gate Handle Replacement - Lift Gate Removal Procedure 1. Remove the screws that retain the liftgate handle. 2. Remove the liftgate handle. Installation Procedure 1. Install the liftgate handle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the screws that retain the liftgate handle. Tighten the screws that retain the liftgate handle to 4 N.m (35 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9207 Tailgate Release Handle: Service and Repair Handle Replacement - Rear Door Inside Handle Replacement - Rear Door Inside Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . 2. Remove the water deflector. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 3. Remove the control rod (1) from the door lock. 4. Remove the door handle nuts (2). 5. Remove the door handle from the door. Installation Procedure 1. Install the door handle to the door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Handle and Lock Cylinder - Rear Door Outside > Page 9208 Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door handle nuts (2). Tighten the nuts to 11 N.m (97 lb in). Important: Install new control rod retainers whenever they are removed. 3. Install the control rod to the door handle (1). 4. Install the water deflector. Refer to Water Deflector Replacement (See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair) . 5. Install the door trim panel. Refer to Trim Panel Replacement - Rear Door (Cargo Doors) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (Cargo Doors))Trim Panel Replacement - Rear Door (E54) (See: Interior Moulding / Trim/Console/Service and Repair/Trim Panel Replacement - Rear Door (E54)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Service and Repair Tailgate Striker: Service and Repair Lock Striker Replacement - Upper and Lower Removal Procedure 1. Remove the bolts that retain the striker. 2. Remove the striker from the vehicle. Installation Procedure 1. Install the lock striker to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts that retain the lock striker to the vehicle. Tighten the bolts that retain the lock striker to 8 N.m (71 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Removal Procedure 1. Disconnect the windshield washer hoses from the windshield wiper arm. 2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 3. Remove the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Remove the air inlet grille panel to cowl screws. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Install the air inlet grille panel to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the air inlet grille panel to cowl screws. Tighten the air inlet grille panel to cowl screws 2 N.m (18 lb in). 3. Install the antenna. Refer to Fixed Antenna Mast Replacement in Entertainment. 4. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the interior garnish moldings. 2. Use the J 38778 in order to pull the weatherstrip from the pinchweld flange of the door. Start at the upper right corner (6), and pull the weatherstrip down (5,4). Keep pulling the weatherstrip (3) until you reach the top (1) of the door, and have pulled the weatherstrip free. Installation Procedure Important: Ensure that the weatherstrip length is equally distributed around the door opening. 1. Partially attach the weatherstrip to the pinchweld flange in 6 key areas (1,2,3,4,5,6). Important: Fit the weatherstrip to the opening by hand. 2. Seat the weatherstrip onto the pinchweld flange to approximately 154 mm (6 in) on each side of the corner in order to install the weatherstrip at each corner (6,4,3,1). Important: Use a rubber mallet and hit the weatherstrip square to the flange. Otherwise, an undesirable spreading of the carrier will occur that will result in reduced retention. 3. Use a rubber mallet in order to install the weatherstrip into each corner. 4. Use a rubber mallet in order to install the pinchweld flange areas of the hinge and the windshield pillars. 5. Ensure that the following conditions are met: * The weatherstrip fits into the corner and matches the radius of the pinchweld flange. * The weatherstrip is seated completely onto the flange in all areas, resulting in a smooth vinyl-trim around the entire door opening. * There is not any distortion or excess spreading of the carrier as a result of hitting the carrier improperly with the rubber mallet. * The weatherstrip is not kinked or distorted after installation. * The weatherstrip is lubricated with GM weatherstrip silicone lube. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 9221 * Install the interior garnish moldings. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Remove the rear hood seal retainers by using J 38778 . 2. Remove the rear hood seal from the hood. Installation Procedure 1. Install the rear hood seal to the hood. 2. Push the retainers into the hood in order to retain the rear hood seal. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Quarter Window Glass Weatherstrip > Component Information > Service and Repair Quarter Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Swing Out Window Removal Procedure 1. Open the swing out window. 2. Pull the weatherstrip from the pinch weld flange. 3. Grasp the weatherstrip at the lower corner and pull up and away from the pinch-weld. Installation Procedure 1. Install the weatherstrip to the pinch-weld flange. 2. Put the weatherstrip on the pinch-weld flange and push downward until fully seated. 3. Close the swing out window. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Outer Belt Sealing Strip Replacement - Outer Belt Removal Procedure 1. Roll the window down. 2. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 3. Remove the outer sealing strip from the door frame. Installation Procedure 1. Install the outer sealing strip to the door frame. 2. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9235 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (Cargo Doors) Weatherstrip Replacement - Rear Door (Cargo Doors) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers (2). 2. Use the 3M Release Agent or an equivalent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic weather retainers (3). 4. Remove the weatherstrip (1) from the left door. 5. Remove the weatherstrip from the right door. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip to the right door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9236 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the weatherstrip (3) to the left door. 3. Install the plastic retainers (2) into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9237 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door (E54) Weatherstrip Replacement - Rear Door (E54) Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Use the J 38778 in order to remove the retainers. 2. Use 3M Release Agent in order to break the weatherstrip adhesive bond. 3. Use the J 38778 in order to remove the plastic retainers. 4. Remove the left door weatherstrip. 5. Remove the right door weatherstrip. Installation Procedure 1. Use 3M Weatherstrip adhesive or an equivalent in order to install the right door weatherstrip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Outer Belt > Page 9238 2. Use 3M Weatherstrip adhesive or an equivalent in order to install the left door weatherstrip. 3. Install the plastic retainers into place. Push the retainers into place until the retainers are fully seated. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Lift Gate Removal Procedure 1. Remove all of the interior trim in order to access the weatherstrip. 2. Pull the weatherstrip from the pinch-weld flange. Start at the upper right corner. Installation Procedure Important: The weatherstrip attaches to the pinch-weld flange in 6 areas. The weatherstrip length distributes equally around the door opening. 1. Install the weatherstrip at the top right corner. Seat the weatherstrip onto the pinch-weld flange. 2. Position and install the weatherstrip by hand. 3. Using a rubber mallet during the final installation may be required in the thick flange areas and in each corner. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module (CCM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 9246 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the cruise control cable. 2. Disconnect the electrical connector. 3. Remove the cruise control module bolts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module bolts. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable. 5. Perform the functional check. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9250 Cruise Control Servo Cable: Service and Repair REMOVAL PROCEDURE 1. Open the hood. 2. Remove the engine cover. NOTE: Do not remove the C-clip from the cruise control connector. The C-clip was not designed for removal. Damage may occur when removing. 3. Do not remove the C-clip from the cruise control end connector. 4. Do not remove the adjuster screw from the end of the cruise control cable. Adjustments will not be needed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9251 5. Remove the cruise control cable from the throttle linkage, using a suitable tool in order to lightly pry off the end of the cruise control cable. 6. Disconnect the cruise control cable from the throttle linkage. 7. Disconnect the cruise control cable from the cable bracket (1). 8. Remove the screw that retains the cruise control cable to the HVAC module (2). 9. Remove the cruise control cable from the cruise control module housing. IMPORTANT: Do not allow the cruise control ribbon to retract into the module assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9252 10. Disconnect the cruise control cable bead (2) from the end of the ribbon (1). 11. Remove the cruise control cable from the vehicle. INSTALLATION PROCEDURE 1. Install the cruise control cable to the vehicle. 2. Remove all bends and twists from the cruise control module ribbon and cable by rotating until removed. Important: ^ Do not twist the cruise control module ribbon (1). ^ Pull the cruise control cable (2) in order to verify retention to the ribbon (1). 3. Attach the cruise control cable bead (2) to the cruise control module ribbon (1). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9253 4. Inspect the orientation of the cruise control ribbon buckle to the cable end fitting. 5. Install the cruise control cable to the cable bracket (1). 6. Install the screw that retains the cruise control cable to the HVAC module (2). 7. Install the cruise control cable to the cruise control module housing. 8. Connect the cruise control cable to the throttle linkage. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9254 9. Snap the cruise control cable fitting (3) into the cruise control module (4). 10. In order to install a new cruise control cable, pull the cruise control cable ferrule through the opposite end of the fitting. The ferrule color is natural and must be visible when pulled through the fitting. 11. From inside the vehicle, snap the cable fitting onto the stud on the throttle body linkage. IMPORTANT: Verify that the cable fitting locking tabs are expanded, and that the tabs are locked in the accelerator bracket hole. 12. Reroute and insert the cruise control cable fitting into the round hole in the accelerator bracket. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9255 13. When installing a new cruise control cable or adjusting an old cruise control cable (3), engage the lock (1) on the cruise control adjuster (2). The white paint mark will disappear when the adjuster is locked. 14. Install the cruise control cable to the HVAC module by placing the cable inside the module clip and snapping the clip closed. 15. Perform the Cruise Control System Functional Test. Refer to Cruise Control Inoperative/Malfunctioning. 16. If the cruise control cable (3) requires adjustment, release the lock on the cable adjuster (2) using the following steps: 16.1. Gently squeeze the tabs on the adjuster plunger (1). 16.2. Pull upward on the adjuster plunger (1). 16.3. Rotate the black plastic screw on the cruise control cable end that connects to the throttle body until the proper lash is achieved. SPECIFICATION The lash should be within 0.0-0.6 mm (0.0-0.024 in). 17. After completing the adjustment, reset the lock. 18. Install the engine cover. 19. Close the hood. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module (CCM) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 9263 Cruise Control Module: Service and Repair REMOVAL PROCEDURE 1. Remove the cruise control cable. 2. Disconnect the electrical connector. 3. Remove the cruise control module bolts. 4. Remove the cruise control module. INSTALLATION PROCEDURE 1. Install the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module bolts. Tighten Tighten the cruise control module bolts to 12 N.m (106 lb in). 3. Connect the electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable. 5. Perform the functional check. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation ABS Indicator The IPC illuminates the ABS indicator when the following occurs: ^ The electronic brake control module (EBCM) detects an ABS-disabling malfunction. The IPC receives a class 2 message from the EBCM requesting illumination. ^ The IPC performs the bulb check. ^ The IPC detects a loss of class 2 communications with the EBCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Audible Warning Device: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9291 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9292 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9293 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9294 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9295 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9296 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 Audible Warning Device: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9308 Audible Warning Device: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation Brake Warning Indicator The instrument panel cluster (IPC) illuminates the brake warning indicator when the following occurs: ^ The body control module (BCM) detects that the park brake is engaged. The IPC receives a class 2 message from the BCM requesting illumination. ^ The EBCM detects a low brake fluid condition and sends a class 2 message to the IPC. ^ The IPC performs the bulb check. ^ An ABS-disabling malfunction also disables dynamic rear proportioning (DRP). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 9315 Brake Warning Indicator: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Hydraulic System Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9320 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9321 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9322 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9323 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9324 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9325 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9326 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9327 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9328 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9329 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9330 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9331 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9332 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9333 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9334 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9335 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9336 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9337 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9338 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9340 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9341 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 Cigar Lighter Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 Cigar Lighter/Auxiliary Outlets Schematics Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection Compass: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9361 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Headlamp And Panel Dimmer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Front > Page 9369 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9374 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9375 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9376 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9377 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9378 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9379 Driver/Vehicle Information Display: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9380 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9381 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9382 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9383 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9384 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9385 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9386 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9387 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9388 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9389 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9390 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Driver/Vehicle Information Display: Connector Views Ambient Air Temperature Sensor (DIC) Driver Information Center (DIC) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Driver/Vehicle Information Display: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 9407 Driver/Vehicle Information Display: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 Fuel Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9421 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9435 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9436 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9437 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9438 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9439 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9440 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9441 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9442 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9443 Fuel Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 9444 Fuel Gauge: Description and Operation The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: ^ The PCM detects a malfunction in the fuel level sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. When the IPC detects that the fuel level is less than 17 percent, the IPC illuminates the low fuel indicator. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 9445 Fuel Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications Fuel Level Specifications The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 9449 Fuel Pump And Sender Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 9450 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 9451 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling Air Bag(s) Arming and Disarming: Service and Repair Disabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. 1. Turn the steering wheel until the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition. IMPORTANT: With the AIR BAG Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation and does not indicate an SIR system malfunction. 4. Remove the AIR BAG Fuse from the IP fuse block. 5. Remove the sound insulator, if equipped. 6. Remove the connector position assurance (CPA) from the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Disconnect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 8. Remove the instrument panel extension. 9. Remove the CPA (2) from the IP module yellow 2-way connector (1) located under the instrument panel extension. 10. Disconnect the IP module yellow 2-way connector (1) located under the instrument panel extension. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling > Page 9457 Air Bag(s) Arming and Disarming: Service and Repair Enabling 1. Remove the key from the ignition. 2. Connect the IP module yellow 2-way connector (1) located under the instrument panel extension. 3. Install the connector position assurance (CPA) (2) to the IP module yellow 2-way connector (1) located under the instrument panel extension. 4. Install the instrument panel extension. 5. Connect the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 6. Install the CPA to the steering wheel module yellow 2-way connector (1) located at the base of the steering column. 7. Install the sound insulator, if equipped. 8. Install the AIR BAG Fuse to the IP fuse block. 9. Staying well away from the air bags, turn ON the ignition, with the engine OFF. 9.1. The AIR BAG indicator will flash 7 times. 9.2. The AIR BAG indicator will then turn OFF. 10. Perform Diagnostic System Check - SIR if the AIR BAG indicator does not operate as described. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Always On CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Steps 1-6 The numbers below refer to the step numbers on the diagnostic table. 2. This step determines if the condition is with the MIL control circuit or the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 9465 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Inoperative CIRCUIT DESCRIPTION Battery positive voltage is supplied directly to the malfunction indicator lamp (MIL). The powertrain control module (PCM) turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON and the engine OFF. MIL OPERATION The MIL is located on the instrument panel. MIL FUNCTION ^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible. ^ The MIL illuminates during a bulb test and a system test. ^ A DTC will be stored if a MIL is requested by the diagnostic test. MIL ILLUMINATION ^ The MIL will illuminate with ignition switch ON and the engine not running. ^ The MIL will turn OFF when the engine is started. ^ The MIL will remain ON if the self-diagnostic system has detected a malfunction. ^ The MIL may turn OFF if the malfunction is not present. ^ If the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition switch is ON. ^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON. DIAGNOSTIC AIDS If the problem is intermittent, refer to Intermittent Conditions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions TEST DESCRIPTION Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Malfunction Indicator Lamp (MIL) Always On > Page 9466 Steps 1-14 The numbers below refer to the step numbers on the diagnostic table. 3. This step determines if the condition is with the MIL control circuit or the PCM. 4. This step determines if a voltage is constantly being applied to the control circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and the trip mileage as determined by the IPC. The IPC calculates the mileage based on the vehicle speed signal from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 9470 Odometer: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation ENGINE OIL PRESSURE GAGE The IPC displays the engine oil pressure as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine oil pressure. The engine oil pressure gage defaults to 0 kPa (0 psi) or below if: ^ The PCM detects a malfunction in the engine oil pressure sensor circuit. ^ The IPC detects a loss of class 2 communications with the PCM. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Engine Oil Pressure (EOP) Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation Brake Lamp The BRAKE warning lamp on the instrument cluster turns on when the park brake is applied. The BRAKE lamp can also be turned on by the switch in the combination valve and the antilock brake system. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 9483 Parking Brake Warning Lamp: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the park brake warning lamp switch electrical connector. 2. Remove the retainer from the switch. 3. Remove the park brake indicator switch (1) from the vehicle. Installation Procedure 1. Install the park brake indicator switch (1) to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the retaining screw. ^ Tighten the retaining screw to 4 Nm (35 inch lbs.). 3. Install the park brake indicator switch electrical connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair Audible Warning Device Control Module: Service and Repair MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the multifunction alarm assembly from the convenience center located under the left side of the instrument panel. 2. Release the single tab connector on the top of the assembly. 3. Pull out the single tab connector. INSTALLATION PROCEDURE 1. Install the multifunction alarm assembly to the convenience center. 2. Align the retaining tab. 3. Press the tab in place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Fasten Safety Belt Indicator/Chime Inoperative Seat Belt Reminder Lamp: Testing and Inspection Fasten Safety Belt Indicator/Chime Inoperative Steps 1-4 Steps 5-11 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection > Fasten Safety Belt Indicator/Chime Inoperative > Page 9492 Steps 1-9 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Headlamp And Panel Dimmer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Front > Page 9501 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications Fuel Level Specifications The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 9505 Fuel Pump And Sender Assembly Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 9506 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The Powertrain Control Module ( PCM) sends the fuel level information via the class 2 circuit to the Instrument Panel Cluster (IPC). This information is used for the IPC fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 9507 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Disconnect the fuel pump electrical connector (5). 3. Remove the fuel level sensor electrical connector retaining clip (6). 4. Disconnect the fuel level sensor electrical connector (7) from under the fuel sender cover. 5. Remove the fuel level sensor retaining clip (4). 6. Squeeze the locking tangs and remove the fuel level sensor (3). INSTALLATION PROCEDURE 1. Install the fuel level sensor (3). 2. Install the fuel level sensor retaining clip (4). 3. Connect the fuel level sensor electrical connector (7). 4. Connect the fuel level sensor electrical connector retaining clip (6). 5. Connect the fuel pump electrical connector (5). 6. Install the fuel sender assembly. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions Tachometer: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9512 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9513 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9514 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9515 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9516 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9517 Tachometer: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9518 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9519 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9520 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9524 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9525 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9526 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9527 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9528 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9529 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9530 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9534 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9535 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9536 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9537 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9541 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9542 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 9543 Tachometer: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 9544 Tachometer: Description and Operation The IPC displays the engine speed based on the information from the PCM. The PCM converts the data from the engine speed sensor to a 2 pulses/engine revolution signal. The IPC uses the engine speed signal circuit (2 pulses/engine revolution) from the PCM in order to calculate the engine speed. If the IPC detects a malfunction in the engine speed signal circuit, the IPC uses the class 2 message from the PCM indicating the engine speed. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 9545 Tachometer: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 Temperature Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9568 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9569 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9570 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9571 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9572 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9573 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9574 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9575 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9576 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Temperature Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Diagrams > Page 9582 Temperature Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions Volt Meter Gauge: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9600 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9601 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9602 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9603 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9604 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9605 Volt Meter Gauge: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9606 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9607 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9608 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9609 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9610 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9611 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9612 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9613 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9614 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9615 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9616 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9617 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9618 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9619 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9620 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9621 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9622 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9623 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9624 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9625 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9626 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9627 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9628 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9629 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9630 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9631 Volt Meter Gauge: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Diagrams > Page 9632 Volt Meter Gauge: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9662 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9663 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9664 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 Ambient Light Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 9672 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 9673 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Backup Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9678 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Page 9679 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 Backup Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9696 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9697 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9698 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9699 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9700 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9701 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9702 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9703 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 Backup Lamp: Connector Views Backup Lamp - Right Backup Lamp - Left Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 Backup Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Page 9715 Backup Lamp: Description and Operation The TURN-B/U fuse in the IP fuse block supplies battery positive voltage to the normally open backup lamp switch. When driver places the gear selector lever is in the REVERSE position, the backup lamp switch closes and the current flow is from the backup lamp switch to the backup lamps. The backup lamps are grounded at G400 and G401. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Page 9716 Backup Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 9721 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 9722 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 9723 Brake Lamp: Diagrams Tail/Stop And Turn Signal Lamp - Left Tail/Stop Lamp - Left - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 9724 Tail/Stop And Turn Signal Lamp - Right Tail/Stop Lamp - Right - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 9725 Brake Lamp: Description and Operation STOPLAMPS The STOP/HAZ fuse in the IP fuse block supplies battery positive voltage to the normally open stoplamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to the multifunction turn signal switch. The current flow is now to the stoplamps which are grounded at G400 and G401. The Center High Mounted Stoplamp (CHMSL) is grounded at G400. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9729 Stop Lamp Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9730 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9731 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations Center Mounted Brake Lamp: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations > Page 9735 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Center Mounted Brake Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 Center Mounted Brake Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9749 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9750 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9751 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9752 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9753 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9754 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9755 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9756 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9757 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9758 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9759 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9760 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9761 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9762 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9763 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9764 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9765 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9766 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9767 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9768 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9769 Center High Mounted Stoplamp (CHMSL) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9770 Center Mounted Brake Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 9771 Center Mounted Brake Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 9772 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the center high-mounted stop lamp retaining screws. 2. Gently pull the electrical connector through the top of the roof. 3. Disconnect the electrical connector. 4. Remove the high-mounted stop lamp from the vehicle. INSTALLATION PROCEDURE 1. Install the high-mounted stop lamp to the vehicle. 2. Connect the electrical connector. 3. Carefully push the electrical connector back into the roof. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the high-mounted stop lamp retaining screws. Tighten Tighten the screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams I/P Compartment Lamp Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 9777 Glove Box Lamp: Description and Operation IP COMPARTMENT LAMP The inadvertent power relay also provides battery positive voltage to the instrument panel compartment lamp. When the IP compartment is opened, the internal switch closes to provide a ground circuit and the IP compartment lamp illuminates. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Locations Daytime Running Lamp Diode Assembly: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Locations > Page 9782 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Locations > Page 9783 Daytime Running Lamps (DRL) Diode Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Diode Assembly > Component Information > Locations > Page 9784 Daytime Running Lamp Diode Assembly: Service and Repair REMOVAL PROCEDURE 1. Remove the body side front lower trim panel. 2. Remove the screw that retains the diode to the body lock pillar. 3. Disconnect the electrical connector from the diode. 4. Remove the diode from the vehicle. INSTALLATION PROCEDURE 1. Install the diode to the vehicle. 2. Connect the electrical connector to the diode. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw that retains the diode to the body lock pillar. Tighten Tighten the screw that retains the diode to the body lock pillar to 6 N.m (53 lb in). 4. Install the body side front lower trim panel. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Service and Repair Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the left side of the knee bolster. 2. Remove the cover (4) from the block to expose the DRL daytime running lights relay. 3. Remove the relay from the block. INSTALLATION PROCEDURE 1. Install the relay to the block. 2. Install the cover (4) to the block for the DRL daytime running lights relay. 3. Install the left side of the knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Headlamp And Panel Dimmer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Front > Page 9799 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Flasher: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Flasher: Recalls Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Flasher: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Flasher: All Technical Service Bulletins Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Technical Service Bulletins > Page 9814 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Technical Service Bulletins > Page 9815 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Open the driver door. 2. In order to remove the flasher module (1) from the instrument panel (IP) convenience center, simultaneously perform the following: 2.1. Lift upward on the tab that retains the flasher module to the IP convenience center. 2.2. Remove the flasher module from the IP convenience center. INSTALLATION PROCEDURE 1. Position the flasher module (1) to the IP convenience center. 2. Engage the flasher module until fully seated and the retaining tab clicks. 3. Close the driver door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9824 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9825 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9826 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9827 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9828 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9829 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9830 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9831 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9832 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9833 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9834 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9835 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9836 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9837 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9838 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9839 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: Recalls Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9849 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9850 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9851 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9852 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9853 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9854 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9855 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9856 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9857 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9858 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9859 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9860 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9861 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9862 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9863 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 9864 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: All Technical Service Bulletins Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Disconnect the electrical connector from the headlamp bulb. CAUTION: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury: Turn off the lamp switch and allow the bulb to cool before changing the bulb. - Leave the lamp switch OFF until the bulb change is complete. - Always wear eye protection when changing a halogen bulb. - Handle the bulb only by its base. A void touching the glass. - Keep dirt and moisture off the bulb. - Properly dispose of the used bulb. - Keep halogen bulbs out of the reach of children. 3. Rotate the bulb counterclockwise in order to disengage the bulb from the headlamp. 4. Remove the bulb from the headlamp. INSTALLATION PROCEDURE 1. Install the bulb to the headlamp. 2. Rotate the bulb clockwise in order to engage the bulb in the headlamp. 3. Connect the electrical connector to the headlamp bulb. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 9883 Headlamp Switch: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Hi-Beam Indicator Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9888 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9889 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9890 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9891 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9892 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9893 Hi-Beam Indicator Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9894 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9895 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9896 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9897 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9898 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9899 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9900 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9901 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9902 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9903 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9904 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9905 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9906 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9907 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9908 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9909 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9910 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9911 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9912 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9913 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9914 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9915 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9916 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9917 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9918 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9919 Hi-Beam Indicator Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams > Page 9920 Hi-Beam Indicator Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations License Plate Lamp: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Page 9931 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9934 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9935 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9936 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9937 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9938 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9939 License Plate Lamp: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9940 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9941 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9942 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9943 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9944 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9945 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9946 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9947 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9948 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9949 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9950 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9951 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9952 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9953 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9955 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 License Lamp Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 License Plate Lamp: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9967 License Plate Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The Body Control Module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9968 License Plate Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9969 License Plate Lamp: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Remove the screws from the license lamp. 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. 2. Install the license lamp. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the license lamp screws. Tighten Tighten the license lamp screws to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations > Page 9973 Map Light: Diagrams Courtesy/Reading Lamp - Center Courtesy/Reading Lamp - Front Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations > Page 9974 Map Light: Service and Repair DOME AND READING LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Release the tab on one end of the lens. 2. Remove the lens by swinging the lens downward. 3. Remove the bulb from the assembly by pulling the bulb straight down. INSTALLATION PROCEDURE 1. Push the bulb up into the contacts/retainers. 2. Align the tabs in the lens with the slots in the assembly. 3. Push the lens into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations Marker Lamp: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9978 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9979 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9980 Locations View Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9981 Marker Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The Body Control Module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9982 Marker Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 9983 Marker Lamp: Service and Repair STEPWELL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the screw that retains the lens. 2. Gently pry off the lens. 3. Pull out the bulb. INSTALLATION PROCEDURE 1. Install the bulb. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the lens to the body with the screw. Tighten Tighten the stepwell lamp body screw to 2 N.m (18 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Convenience Center (Front View) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9990 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9991 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9992 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9993 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9994 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9995 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9996 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10004 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10005 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10012 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10013 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10014 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10015 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10016 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Service and Repair Daytime Running Lamp Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the left side of the knee bolster. 2. Remove the cover (4) from the block to expose the DRL daytime running lights relay. 3. Remove the relay from the block. INSTALLATION PROCEDURE 1. Install the relay to the block. 2. Install the cover (4) to the block for the DRL daytime running lights relay. 3. Install the left side of the knee bolster. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Underhood Fuse Block (Front View) (Part 1 Of 2) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Convenience Center (Front View) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp Relay: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10036 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10037 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10038 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10039 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10040 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10041 Parking Lamp Relay: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10045 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10046 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10047 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10048 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10049 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10050 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10051 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10052 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10053 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10054 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10055 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10056 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10057 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10058 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10059 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10060 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10061 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10062 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10063 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10064 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10065 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10066 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions Ambient Light Sensor: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10073 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10074 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10075 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10076 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10077 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10078 Ambient Light Sensor: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10079 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10080 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10081 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10082 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10083 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10084 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10085 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10086 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10087 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10088 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10089 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10090 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10091 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10092 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10093 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10094 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10095 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10096 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10097 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10098 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10099 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10100 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10101 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10102 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10103 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10104 Ambient Light Sensor Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 10105 Ambient Light Sensor: Electrical Diagrams For further information regarding this component and the system that it is a part of, please refer to Lighting and Horns Diagrams. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 10106 Ambient Light Sensor: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 10107 Ambient Light Sensor: Service and Repair REMOVAL PROCEDURE 1. Lift upward on the center defogger grille located in center of the dash to expose the DRL photo sensor (1) retainer. 2. Turn the DRL photo sensor counterclockwise 1/4 turn in order to remove. 3. Disconnect the electrical connection from the DRL photo sensor (1). INSTALLATION PROCEDURE 1. Connect the electrical connection to the DRL photo sensor (1). 2. Insert the DRL photo sensor (1) and turn counterclockwise 1/4 turn in order to seat. 3. Install the defogger grille located in the center of the dash by push downward. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10111 Stop Lamp Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10112 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the retainer (3) from the brake pedal pin. 3. Unsnap the switch (2) and pushrod (4) from the brake pedal (1) pin. 4. Disconnect the electrical connector. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10113 1. Connect the electrical connector. 2. Install the switch (2) and pushrod (4) onto the brake pedal (1) pin. 3. Install the retainer (3) onto the brake pedal (1) pin. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Front Door Switch: Service and Repair Front REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connector(s). 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connector(s) to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Front > Page 10121 Door Switch: Service and Repair Rear REMOVAL PROCEDURE 1. Loosen the nut on the door jamb switch. 2. Gently pull the switch away from the body. 3. Disconnect the door jamb switch from the electrical connectors. 4. Tape the wiring to the body in order to prevent the wiring from entering the hole in the door pillar. 5. Remove the door jamb switch from the vehicle. INSTALLATION PROCEDURE 1. Install the door jamb switch to the vehicle. 2. Connect the electrical connectors to the door jamb switch. NOTE: Refer to Fastener Notice in Service Precautions. 3. Tighten the nut on the door jamb switch. Tighten Tighten the door jamb switch nut to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10130 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10131 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10132 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10133 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10134 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10135 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10136 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10137 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10138 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10139 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10140 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10141 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10142 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10143 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10144 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10145 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > Recalls for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: Recalls Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement Technical Service Bulletin # 05013A Date: 050526 Recall - Hazard Warning Flasher Switch Replacement Bulletin No.: 05013A Date: May 26, 2005 SAFETY Subject: 05013A - Multifunction Switch Contacts Models: 2001-2002 Chevrolet Astro 2001-2002 GMC Safari Supercede: THE INSPECTION IN STEP 35 OF THE PROCEDURE "REPLACING THE HAZARD WARNING FLASHER SWITCH" HAS BEEN REVISED AND PART NUMBER 15174447 HAS BEEN ELIMINATED. PLEASE REVIEW THIS NEW INFORMATION IMMEDIATELY. DISCARD ALL COPIES OF BULLETIN 05013 ISSUED APRIL 2005. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2001-2002 Chevrolet Astro and GMC Safari vehicles. On some of these vehicles, the stop lamps and rear hazard lamps may become inoperative. The usage factors that increase the possibility of this condition occurring include frequency and length of brake applications, frequency of trailer towing with brake applications, and exposure to high ambient temperatures. The center high mounted stop lamp and turn signal lamp functionality are not affected. The loss of stop lamps and/or rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle accident. Correction Dealers are to inspect and replace the hazard warning flasher switch, if necessary. In a small number of vehicles, the multifunction switch will require replacement. Vehicles Involved Involved are certain 2001-2002 Chevrolet Astro and GMC Safari vehicles built within the VIN breakpoints shown. Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US & Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld (U.S.), GMinfoNet (Canada) Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld/GMinfoNet. For Export For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10155 The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO=Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Product Recall Customer Reimbursement Procedure Form is shown in this bulletin. Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada & Export Customer requests for reimbursement of previously paid repairs to correct the condition addressed in this bulletin are to be submitted by April 30, 2006. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: ^ Proof of ownership at time of repair. ^ Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS. Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification. Courtesy Transportation Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10156 The General Motors Courtesy Transportation Program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for courtesy transportation guidelines. Claim Information Submit a Product Recall Claim with the information shown. Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10157 of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers, possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. GENERAL MOTORS PRODUCT RECALL CUSTOMER REIMBURSEMENT PROCEDURE If you have paid to have this recall condition corrected prior to receiving this notification, you may be eligible to receive reimbursement. Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. Your claim will be acted upon within 60 days of receipt. If your claim is: ^ Approved, you will receive a check from General Motors. ^ Denied, you will receive a letter from General Motors with the reason(s) for the denial, or ^ Incomplete, you will receive a letter from General Motors identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10158 Please follow the instructions on the Claim Form shown to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided on the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center at the number also shown. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday. Disclaimer Service Procedure The following procedure describes how to inspect and replace the hazard warning flasher switch, OR inspect and replace the multifunction (turn signal, headlamp dimmer, and windshield wiper/washer) switch assembly. The part that you replace will be determined during the inspection portion of this procedure. Do NOT replace any parts until after performing the inspection procedure. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10159 Inspection Procedure 1. From inside the vehicle, depress the hazard warning flasher switch located on the top of the steering column. 2. Depress the hazard warning flasher switch again. ^ If the hazard warning flasher switch did not stick in either the up or down position, proceed to the section titled "Replacing the Hazard Warning Flasher Switch." Do not order any replacement parts until instructed to in the additional inspection procedure included in that section. ^ If the hazard warning flasher switch is sticking in either the up or down position, replace the multifunction switch. Proceed to the section titled "Replacing the Multifunction Switch." Replacing the Hazard Warning Flasher Switch This procedure describes how to replace ONLY the hazard warning flasher switch assembly. The procedure includes information on how to remove the original switch, where to apply the lubricant on the new switch, and how to install the new switch. DO NOT use this procedure if the inspection above indicates that the multifunction switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10160 steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 26.1 Tilt the lower steering column trim cover down. 26.2 Slide the lower steering column trim cover backward in order to disengage the locking tabs. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10161 27. Remove the upper steering column trim cover mounting screws (1). 28. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 29. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 30. Turn the ignition lock cylinder to the START position. 31. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. 32. Release the ignition lock cylinder to the RUN position. 33. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 34. Remove the upper column cover. Important: The illustration above is for the purpose of identifying the barcode only. The actual location of the barcode on the switch may differ. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10162 35. Inspect the part number (1) on the multifunction switch at the location shown in the illustration. 36. If the part number is 26084051, 26084052, 26096834, 26096835, 26102157 or 26102158, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If there is NO part number or barcode on the switch, no repair is required. Proceed to the section titled "Reassemble Vehicle." ^ If the part number or barcode on the switch is 26091775 or 26091776, proceed to the next step and replace the hazard warning flasher switch using part number 15177379. Important: Carefully review the above illustration to determine the exact location to insert the screwdriver in the next step. 37. Insert a small, pocket-sized, flat bladed screwdriver (2) into the small space between the hazard warning flasher switch housing (1) and the multifunction switch (3). 38. Carefully tilt the screwdriver handle towards the instrument cluster. This will cause the blade of the screwdriver to pry open the space between the hazard warning flasher switch housing and the multifunction switch. 39. While the space is pried open, pull the hazard warning flasher switch out of the multifunction switch. Discard the hazard warning flasher switch. Note: Do not touch the three triangle-shaped electrical contacts (1) on the side of the switch when removing the protective packaging, handling, or applying grease to the new hazard warning flasher switch in the next steps. 40. Remove the rubber band and protective plastic wrapping from the new hazard warning flasher switch. Important: The electrical contacts on the new hazard warning flasher switch require a special lubricant, which is included in the kit. Only apply this special lubricant as instructed in the next step. DO NOT use any other type of grease or lubricant. 41. Open the container of special grease included in the kit and apply it to the surfaces of the three triangle-shaped electrical contacts (1) on the side of the new hazard warning flasher switch. When properly applied, the surfaces of the three triangle-shaped electrical contacts must be completely covered and there should be no grease left in the container. DO NOT put any grease in the opening that contains the small metal return spring. 42. Insert the hazard warning flasher switch into the opening of the multifunction switch and press down until it locks into place. 43. Remove any excess grease that may appear around the base of the hazard warning flasher switch. Proceed to the next section "Reassemble Vehicle." Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10163 Reassemble Vehicle 1. Install the upper steering column cover. 2. Insert the ignition lock cylinder through the upper shroud. 3. Install the ignition lock cylinder to the lock module by doing the following: 3.1. Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. 3.2. Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 4. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 5. Install the lower steering column trim cover to the upper steering column trim cover. 5.1. Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 5.2. Tilt the lower steering column trim cover up. 5.3. Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 6. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 7. Install the tilt lever. 8. Install the steering wheel to the steering shaft. 9. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 10. Install the horn plunger to the steering column. 11. Position the SIR module near the steering wheel. 12. Connect the SIR electrical connector. 13. Connect the CPA retainer to the SIR connector. 14. Connect the SIR lead wire to the clip on the steering wheel. 15. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring is not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 16. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 17. Rotate the steering wheel back into the straight position. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10164 18. Connect the I/P module yellow 2-way connector located under the I/P extension. 19. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 20. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 21. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 22. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 23. Install the SIR fuse and install the fuse block cover. 24. Be sure that the ignition is in the OFF position. 25. Connect the negative battery. Replacing the Multifunction Switch This procedure describes how to replace ONLY the multifunction switch assembly. The new multifunction switch assembly will come complete with a new hazard warning flasher switch already installed. DO NOT use this procedure if the results of the inspection procedure indicate that only the hazard warning flasher switch requires replacement. Contained in this procedure are unique steps to address features or options such as cruise control, standard or tilt column, and a column-mounted automatic transmission lever. Tools Required ^ J 1859-A Steering Wheel Puller 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery. 3. Remove the SIR fuse from the fuse block. 4. Remove the screws attaching the driver's side knee bolster trim panel underneath the I/P and reposition the panel out of the way. 5. Locate the driver's side yellow 2-way air bag electrical connector at the base of the steering column and remove the connector position assurance (CPA) from the connector. 6. Disconnect the yellow 2-way electrical connector. 7. If equipped, remove the tilt steering column lever. Important: Some of the illustrations included in this procedure show the steering column removed from the vehicle. Those illustrations are for reference Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10165 purposes only. DO NOT remove the steering column from the vehicle to perform this repair procedure. 8. Turn the ignition switch to the RUN position to unlock the steering wheel. 9. Turn the steering wheel 90 degrees so that the side of the SIR module is at the 12 o'clock position in order to gain access to the holes behind the steering wheel. 10. Insert a flat-bladed tool into the access hole and push the leaf spring in order to release the notched pin that retains the inflator module. 11. Turn the steering wheel 180 degrees in order to gain access to the remaining access hole. 12. Insert a screwdriver into the remaining hole and push the leaf spring in order to release the notched pin that retains the inflator module. 13. Tilt the top of the inflator module rearward to gain access to the SIR wiring. 14. Disconnect the SIR lead wire from the clip on the inflator module. 15. Disconnect the SIR lead wire from the clip on the steering wheel. 16. Disconnect the CPA retainer. 17. Disconnect the electrical connector. Caution: When you are carrying an undeployed inflator module: ^ Do not carry the inflator module by the wires or connector on the inflator module. ^ Make sure the bag opening points away from you. ^ When you are storing an undeployed inflator module, make sure the bag opening points away from the surface on which the inflator module rests. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. 18. Set the SIR module aside. 19. Remove the horn plunger from the steering column by pressing inward to the stop and rotate the horn plunger 90 degrees. 20. Remove the steering wheel retaining nut. 21. Install the J 1859-A, Steering Wheel Puller, to the steering wheel. 22. Remove the steering wheel using the J 1859-A. 23. Remove the J 1859-A from the steering wheel. 24. Remove the tilt lever. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10166 25. Remove the screws attaching the lower steering column cover to the steering column. 26. Remove the lower steering column trim cover from the upper steering column trim cover. 27. Tilt the lower steering column trim cover down. 27.1 Slide the lower steering column trim cover backward in order to disengage the locking tabs. 28. Remove the upper steering column trim cover mounting screws (1). 29. Lift the upper steering column trim cover to gain access to the lock cylinder access hole. 30. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole. 31. Turn the ignition lock cylinder to the START position. 32. Using the bent tip awl, push down on the ignition lock cylinder retaining pin. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10167 33. Release the ignition lock cylinder to the RUN position. 34. Remove the ignition lock cylinder from the lock module by pulling the ignition lock cylinder away from the steering column. 35. Remove the upper column cover. 36. Disconnect the steering column electrical connectors. 37. Disconnect the multifunction switch connectors from the steering column electrical connector. 38. Remove the steering column wiring harness from the wiring harness strap. 39. Remove the wire harness straps from the steering column wire harness. 40. Remove the multifunction switch mounting screws. 41. Remove the multifunction switch. Important: The multifunction switch electrical contact must rest on the canceling cam assembly. 42. Install the new multifunction switch as follows: 42.1 Use a small blade screwdriver in order to compress the electrical contact. 42.2 Move the multifunction switch into position. 43. Install the multifunction switch mounting screws. Tighten Tighten the multifunction switch mounting screws to 6 N.m (53 lb in). 44. Connect the multifunction switch electrical connectors to the steering column electrical connector. 45. Connect the steering column electrical connector to the I/P wire harness. 46. Install the wire harness straps to the steering column wire harness. 47. Install the steering column wire harness to the wiring harness strap. 48. Install the upper steering column cover. 49. Insert the ignition lock cylinder through the upper shroud. 50. Install the ignition lock cylinder to the lock module by doing the following: 50.1 Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10168 50.2 Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the lock module. 51. Install the upper steering column cover screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). Important: The shift lever seal must be seated in the covers. 52. Install the lower steering column trim cover to the upper steering column trim cover. 52.1 Match the tab slots on the lower steering column trim cover with the locking tabs on the upper steering column trim cover. 52.3 Tilt the lower steering column trim cover up. 52.3 Slide the lower steering column trim cover forward until the locking tabs snap into the tab slots. 53. Install the lower steering column cover screws. Tighten Tighten the screws to 3.5 N.m (31 lb in). 54. Install the tilt lever. 55. Install the steering wheel to the steering shaft. 56. Install the steering wheel retaining nut. Tighten Tighten the steering wheel retaining nut to 41 N.m (30 lb ft). 57. Install the horn plunger to the steering column. 58. Position the SIR module near the steering wheel. 59. Connect the SIR electrical connector. 60. Connect the CPA retainer to the SIR connector. 61. Connect the SIR lead wire to the clip on the steering wheel. 62. Connect the SIR lead wire to the clip on the inflator module. Important: Verify that the wiring in not exposed or trapped between the inflatable restraint steering wheel module and the steering wheel. 63. Press the inflator module into the steering wheel firmly enough that the module engages and latches the notched pins in the leaf springs. 64. Rotate the steering wheel back into the straight position. 65. Connect the I/P module yellow 2-way connector located under the I/P extension. 66. Install the CPA to the I/P module yellow 2-way connector located under the I/P extension. 67. Connect the steering wheel module yellow 2-way connector located at the base of the steering column. 68. Install the CPA to the steering wheel module yellow 2-way connector located at the base of the steering column. 69. Position the knee bolster trim panel to the I/P and install the attaching screws. Tighten Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10169 Tighten the screws to 1.9 N.m (17 lb in). 70. Install the SIR fuse and install the fuse block cover. 71. Be sure that the ignition is in the OFF position. 72. Connect the negative battery cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > 05013A > May > 05 > Recall - Hazard Warning Flasher Switch Replacement > Page 10170 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hazard Warning Switch: > NHTSA05V099000 > Mar > 05 > Recall 05V099000: Brake/Hazard Lamp Failure Hazard Warning Switch: All Technical Service Bulletins Recall 05V099000: Brake/Hazard Lamp Failure MAKE/MODELS: MODEL/BUILD YEARS: Chevrolet/Astro 2001-2002 GMC/Safari 2001-2002 MANUFACTURER: General Motors Corp. NHTSA CAMPAIGN ID NUMBER: 05V099000 RECALL DATE: March 09, 2005 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 77055 SUMMARY: On certain minivans, the multifunction switch may develop an open circuit condition in the stop lamp or hazard lamp circuit that results in the stop lamps and hazard lamps being inoperative. CONSEQUENCE: The loss of stop lamps and rear hazard lamps could fail to warn a following driver that the vehicle is braking and/or is stopped and could lead to a vehicle crash. REMEDY: Dealers will replace the hazard warning flasher switch and apply special grease to the contacts at the time of installation of the module. The repair would be used in vehicles in which the hazard slider button is still movable. If a vehicle has a hazard slider button that is not movable (frozen), the entire multifunction switch will be replaced. The manufacturer has not yet provided an owner notification schedule. Owners should contact Chevrolet at 1-800-630-2438 or GMC at 1-866-996-9463. NOTES: GM recall No. 05013. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10178 Headlamp Switch: Service and Repair REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the instrument panel cluster trim plate. 3. Remove the switch from the plate by using the following procedure: 3.1. Release the retaining tabs on the sides of the switch. 3.2. Pull the switch out of the plate. 3.3. Disconnect the electrical connector(s) at the back of the headlamp switch. INSTALLATION PROCEDURE 1. Connect the electrical connector(s) to the back of the switch. 2. Install the headlamp switch to the plate by snapping the switch into place. 3. Install the instrument panel cluster trim plate. 4. Connect the battery negative cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10186 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 10187 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 10188 Tail Lamp: Diagrams Tail/Stop And Turn Signal Lamp - Left Tail/Stop Lamp - Left - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 10189 Tail/Stop And Turn Signal Lamp - Right Tail/Stop Lamp - Right - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 10190 Tail Lamp: Description and Operation PARK, TAIL, MARKER AND LICENSE LAMPS The park, tail, marker and license lamps are turned on when the headlamp switch is placed in the PARK or ON position or anytime the headlights are requested. The PK LPS fuse in the IP fuse block supplies battery positive voltage to the park lamp relay and the headlamp switch. The Body Control Module (BCM) provides a ground, or control circuit, to the park lamp relay coil circuit during ALC operation. When the park lamps are turned on during ALC, the BCM energizes the park lamp relay. The park lamps can also be supplied battery positive voltage directly from the headlamp switch. Current flow is to the park, tail, marker and license lamps. The front park and marker lamps are grounded at G100 and G101. The rear park, tail, marker and license lamps are grounded at G400 and G401. If the headlight switch is left in the ON position, the park, tail and marker lamps will remain on until turned off or the battery runs dead. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 10191 Tail Lamp: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Open the rear doors. 3. Remove the screws that retain the tail lamp to the body. 4. Remove the lamp sockets from the back of the tail lamp by using the following procedure: 4.1. Squeeze the tang at the electrical connector. 4.2. Turn the bulb and the base. IMPORTANT: Do not remove the grease from the socket. 5. Remove the bulbs from the sockets. INSTALLATION PROCEDURE 1. Apply a light coating of lithium grease to the sockets if there is no grease in the sockets. 2. Install the bulbs into the sockets. 3. Install the lamp sockets to the back of the tail lamp. 4. Install the tail lamp to the body. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the screws to retain the tail lamp to the body. Tighten Tighten the tail lamp screws to 3 N.m (27 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair Trunk Lamp: Service and Repair IP STORAGE COMPARTMENT LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the instrument panel storage compartment. 2. Gently depress the tabs at the top and the bottom of the compartment lamp switch by using a small flat-bladed tool. 3. Remove the compartment lamp switch. 4. Disconnect the electrical connector from the switch. 5. Pull the bulb from the compartment lamp switch. INSTALLATION PROCEDURE 1. Install the bulb to the compartment lamp switch. 2. Connect the electrical connector to the switch. 3. Install the compartment lamp switch and press in order to engage the tabs. 4. Close the instrument panel storage compartment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Service and Repair Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Open the driver door. 2. In order to remove the flasher module (1) from the instrument panel (IP) convenience center, simultaneously perform the following: 2.1. Lift upward on the tab that retains the flasher module to the IP convenience center. 2.2. Remove the flasher module from the IP convenience center. INSTALLATION PROCEDURE 1. Position the flasher module (1) to the IP convenience center. 2. Engage the flasher module until fully seated and the retaining tab clicks. 3. Close the driver door. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10203 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10204 Turn Signal Lamp: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10205 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10206 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10207 Turn Signal Lamp: Diagrams Park/Turn Signal Lamp - LF Park/Turn Signal Lamp - RF Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10208 Park/Turn Signal Lamp - LF - Export Park/Turn Signal Lamp - RF - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10209 Tail/Stop And Turn Signal Lamp - Left Tail/Stop And Turn Signal Lamp - Right Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10210 Turn Signal Lamp - LR - Export Turn Signal Lamp - RR - Export Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10211 Turn Signal Lamp: Description and Operation The STOP/HAZ fuse in the IP fuse block supplies battery positive voltage to the multifunction hazard switch assembly. The TURN-B/U fuse in the IP fuse block supplies Ignition positive voltage to the multifunction turn signal switch assembly. With the ignition switch in the RUN or START position, ignition positive voltage is connected through the multifunction turn signal and hazard switch assembly to the flasher module which is grounded at G105. When the turn signal switch is placed in either the left or right position, the circuit is complete from the flasher module to the turn signal lamps and to ground. The flasher module then sends an on-off voltage signal to either the left or right turn signals and their Instrument Panel Cluster (IPC) indicator. When the hazard switch is activated, all turn signal lamps will flash including both IPC turn indicators. The front turn signals are grounded at G101 and G100. The rear turn signals are grounded at G400 and G401. On the export vehicle, the rear turn signal lamps are separate amber lamps utilizing single filament bulbs grounded at G400 and G401. There are also amber side repeater lamps on each fender which are grounded at G101 and G110. The front side marker lamps stay on steady and do not flash alternately with the turn signals as the domestic vehicle does due to they are grounded directly to G101 and G100. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Technical Service Bulletins > Page 10212 Turn Signal Lamp: Service and Repair PARK/TURN SIGNAL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn OFF the headlamp switch. 2. Remove the mounting screws. 3. Remove the park/turn signal lamp from the vehicle. 4. Remove the lamp sockets from the park/turn signal lamp housing. 5. Remove the bulbs from the lamp sockets. INSTALLATION PROCEDURE 1. Install the bulbs into the lamp sockets. 2. Install the lamp socket to the park/turn signal lamp housing. 3. Install the park/turn signal lamp to the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the mounting screws. Tighten Tighten the mounting screws to 1.4 N.m (12 lb in). Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Page 10216 Vanity Lamp: Diagrams Vanity Mirror Lamp - Left Vanity Mirror Lamp - Right Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Page 10217 Vanity Lamp: Description and Operation The inadvertent power relay also provides battery positive voltage to each vanity mirror lamp. When the vanity mirror cover on the sunshade is opened, the internal switch closes to provide a ground circuit and the vanity lamp illuminates. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Page 10218 Vanity Lamp: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Lighting and Horns Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Page 10219 Vanity Lamp: Service and Repair VANITY MIRROR LAMP REPLACEMENT REMOVAL PROCEDURE 1. Turn the sunshade down. 2. Lift the vanity mirror cover. 3. Remove the lens by gently prying at the top or the bottom of the lens with a suitable flat bladed tool. 4. Lift the bulb(s) straight out. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Page 10220 1. Press the bulb(s) in. 2. Install the lens. 3. Close the vanity mirror cover. 4. Turn the sunshade up. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10230 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10231 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10232 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10238 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10239 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10240 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Component Locations Heated Glass Element: Component Locations Locations View In the rear window of the vehicle Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Component Locations > Page 10243 Heated Glass Element: Connector Locations Locations View Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10246 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10251 Heated Glass Element: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10252 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10253 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10254 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10255 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10256 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 Heated Glass Element: Connector Views Rear Window Defogger Grid Connector - Left Hand Rear Window Defogger Grid Connector - Right Hand Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10278 Defogger Schematics Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection ^ Inspect for aftermarket devices which could affect the operation of the Rear Window Defogger System. Refer to Checking Aftermarket Accessories in Diagrams. See: Diagrams/Diagnostic Aids ^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in Diagrams. Symptom List Refer to a symptom diagnostic procedure from the following list in order 10 diagnose the symptom: ^ Defogger Inoperative - Rear Window ^ Defogger Indicator Always On ^ Defogger Grid Lines Diagnosis Steps 1-4 Steps 5-7 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 10281 Steps 1-7 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 10282 Steps 8-16 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 10283 Heated Glass Element: Component Tests and General Diagnostics 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. ^ If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. Refer to Testing for Intermittent and Poor Connections and Connector Repairs in Diagrams. ^ If the test lamp goes out, test the grid line in at least 2 places ((1) and (3)) to eliminate the possibility of bridging the open (2) in the grid line. 5. Once the open (2) is located, repair the grid line. Refer to Grid Line Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Page 10284 Heated Glass Element: Service and Repair Rear Window Defogger Braided Lead Wire Caution: Refer to Glass and Sheet Metal Handling Caution in Cautions and Notices. 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: * The rear defogger bus bar lead wire * The defogger terminal repair area Caution: Refer to Window Retention Caution in Cautions and Notices. Important: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 7. Align the spots with the flux to the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: * The underside of the rear defogger bus bar lead wire * The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: * The rear defogger bus bar lead wire * The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: * The top of the rear defogger bus bar lead wire * The defogger terminal Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Page 10285 Important: Do not remove the holding force until the solder has solidified. 14. Remove the excess flux with the solvent. 15. Connect the electrical connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 10290 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 Rear Defogger: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10302 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10303 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10304 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10305 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10306 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10307 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10308 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10309 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10310 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10311 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10312 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10313 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10314 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10315 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10316 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10317 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10318 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10319 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10320 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10321 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10322 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 10323 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Page 10324 Rear Defogger: Testing and Inspection For information regarding this component and the system that it is a part of, please refer to Heated Glass Element Testing and Inspection. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams Power Window Control Module: Diagrams Rear Window Wiper/Washer Module Windshield Wiper Motor And Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10334 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10335 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10336 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10337 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10338 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10339 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10340 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10341 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10342 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10343 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10344 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10345 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10346 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10347 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10348 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10349 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10350 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10351 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10352 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10353 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10354 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10355 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10356 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10357 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10358 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10359 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10360 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10361 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10362 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10363 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10364 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10365 Power Window Switch: Connector Views Window Master Switch - Driver C1 Window Switch - Front Passenger C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10366 Window Master Switch - Driver C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10367 Window Switch - Front Passenger C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams Power Window Control Module: Diagrams Rear Window Wiper/Washer Module Windshield Wiper Motor And Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Motor Replacement - Power Window Removal Procedure 1. Remove the power window regulator. Refer to Window Regulator Replacement (See: Window Regulator/Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install a self-tapping, pan head sheet metal screw through the sector gear and the backing plate at the hole provided. This will lock the sector gear into position. 3. Drill out the rivets (2) attaching the power window motor to window regulator . 4. Remove the power window motor from the window regulator (3). Installation Procedure 1. Install the power window motor to the window regulator (3). Caution: Do not attempt to service the regulator motor without releasing the counterbalance spring tension. The regulator lift arm is under tension from the counterbalance spring and can cause personal injury if the motor is removed from the regulator. 2. Install the rivets (2) attaching the power window motor to window regulator . 3. Remove the self-tapping, pan head sheet metal screw through the sector gear and the backing plate hole. 4. Install the power window regulator. Refer to Window Regulator Replacement (See: Window Regulator/Front Door Window Regulator/Service and Repair/Door Window Regulator Replacement (Manual)) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Utility/Van Zoning All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The table explains the numbering system. Electrical Symbols Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10380 Electrical Symbols Part 1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10381 Electrical Symbols Part 2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10382 Electrical Symbols Part 3 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10383 Electrical Symbols Part 4 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10384 Electrical Symbols Part 5 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10385 Power Window Switch: Diagnostic Aids Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Handling Caution in Service Precautions. ^ SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. ^ OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: ^ Power feeds connected to points other than the battery ^ Antenna location ^ Transceiver wiring located too close to vehicle electronic modules or wiring ^ Poor shielding or poor connectors on antenna feed line ^ Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: ^ Wiggling the harness ^ Disconnecting a connector and reconnecting ^ Stressing the mechanical connection of a connector ^ Pulling on the harness or wire in order to identify a separation/break inside the insulation ^ Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these oases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Diagrams/Diagnostic Aids Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10386 J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: ^ Turn ON the ignition, with the engine OFF. ^ Turn ON the engine. ^ Turn ON the circuit and/or system with a scan tool in Output Controls. ^ Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10387 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a 'first in, first out' basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: ^ Snapshot - taken from the Snapshot menu choice ^ Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting three parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10388 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. ^ Testing for Short to Ground See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Short to Ground ^ Testing for Continuity See: General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity ^ Testing for Short to Voltage See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For a Short To Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Troubleshooting With A Digital Multimeter 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing an Intermittent Fault Condition. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. ^ If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. ^ If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: ^ Wiring broken inside the insulation ^ Poor connection between the male and female terminal at a connector-Refer to Testing for Proper Terminal Contact for the specific procedure. See: General Electrical Diagnostic Procedures/Circuit Testing/Testing For Proper Terminal Contact ^ Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. ^ Wire insulation which is rubbed through- This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. ^ Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. See: General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions ^ Refer to Testing for Electrical Intermittent for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Diagrams/Diagnostic Aids ^ Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. See: General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure Testing For Proper Terminal Contact TOOLS REQUIRED ^ J 42675 flatware Probe Adapter ^ J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10389 It is important to test terminal contact at the component and any on-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-B or the J 38125-4 for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-B, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). ^ When the DMM displays voltage the short is in the wiring leading to the first connector or switch. ^ If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Circuit Testing The Circuit Testing contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10390 ^ Using Connector Test Adapters ^ Probing Electrical Connectors ^ Troubleshooting with a Digital Multimeter ^ Troubleshooting with a Test Lamp ^ Using Fused Jumper Wires ^ Measuring Voltage ^ Measuring Voltage Drop ^ Measuring Frequency ^ Testing for Continuity ^ Testing for Short to Ground ^ Testing for a Short to Voltage Probing Electrical Connectors IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Backprobe IMPORTANT: ^ Backprobe connector terminals only when specifically required in diagnostic procedures. ^ Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. ^ Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. ^ After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Troubleshooting With A Digital Multimeter NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: ^ Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: General Electrical Diagnostic Procedures/Troubleshooting Tools/Probing Electrical Connectors ^ Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. ^ If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TOOLS REQUIRED Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10391 J 34142-B 12 V Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-A Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Fuses Circuit Protection - Fuses Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10392 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips General Information The Connector Repairs contains the following types of connector repair information. Using these elements together will make connector repair faster and easier: ^ Connector Position Assurance Locks ^ Terminal Position Assurance Locks ^ Push to Seat Connectors ^ Pull to Seat Connectors ^ Weather Pack Connectors ^ Repairing Connector Terminals Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10393 ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Pull to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair pull-to-seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves. 3. Using the proper pick or removal tool insert into the front of the connector body. 4. Grasp the wire at the back of the connector body and gently pull the terminal (1) from the connector body (3). 5. Inspect the terminal for damage, if damaged refer to Terminal Repair. 6. Reform the locking tang (2) if the terminal is being reused. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. TERMINAL INSTALLATION 1. Inspect the terminal for damage. If damaged refer to Terminal Repair. 2. Reform the locking tang (2) if the terminal is being reused. 3. Ensure that the cable seal is kept on the terminal side of the splice. 4. Insert the wire into the back of the connector body. Push until the terminal locking tang locks into the connector body. 5. Install the TPA, CPA and/or the secondary locks. Push to Seat Connectors TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10394 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10395 TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs. See: Diagrams/Diagnostic Aids 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Repairing Connector Terminals TOOLS REQUIRED J 38125-B Terminal Repair kit Use the following repair procedures in order to repair the following. ^ Push to Seat terminals ^ Pull to Seat terminals ^ Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-B contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals. Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Weather Pack Connectors The following is the proper procedure for the repair of Weather Pack(R) Connectors. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10396 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals See: General Electrical Diagnostic Procedures/Wiring Repairs/Connector Repairs/Repairing Connector Terminals 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. General Information The Wiring Repairs contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: ^ Circuit Protection - Fuses ^ Circuit Protection - Circuit Breakers ^ Circuit Protection - Fusible Links ^ Repairing Damaged Wire Insulation ^ Splicing Copper Wire Using Splice Clips ^ Splicing Copper Wire Using Splice Sleeves ^ Splicing Twisted or Shielded Cable ^ Splicing Inline Harness Diodes ^ Heated Oxygen Sensor (HO2S) Wiring Repairs ^ SIR/SRS Wiring Repairs Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10397 ^ Flat Wire Repairs Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: General Electrical Diagnostic Procedures/Wiring Repairs/Typical Electrical Repairs/Splicing Copper Wire Using Splice Clips SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: ^ The SDM harness connector pigtail assembly ^ The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair TOOLS REQUIRED J 38125-B Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-8. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10398 ^ Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. ^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. ^ Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: ^ When adding a length of wire to the existing harness, use the same size wire as the original wire. ^ Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. ^ Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. ^ Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. ^ If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-B in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10399 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: ^ The tubing will shrink completely as the heat is moved along the insulation. ^ A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Copper Wire Using Splice Clips TOOLS REQUIRED J 38125-B Terminal Repair Kit Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10400 Wire Size Conversion 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original (except fusible link). ^ The wire's insulation must have the same or higher temperature rating. Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-B in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. ^ Ensure that the wires extend beyond the clip in each direction. ^ Ensure that no insulation is caught under the clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10401 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10402 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves TOOLS REQUIRED J 38125-B Terminal Repair Kit Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. ^ Cut as little wire off the harness as possible. ^ Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10403 bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. ^ The wire must be of equal or greater size than the original. ^ The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. ^ Select the correct size opening in the wire stripper or work down from the largest size. ^ Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-B crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-B until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. ^ Using the heat torch apply heat to the crimped area of the barrel. ^ Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10404 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. ^ Rewrap the conductors with the mylar tape. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10405 ^ Use caution not to wrap the drain wire in the tape (1). ^ Follow the splicing instructions for copper wire and splice the drain wire. ^ Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. ^ If the harness is taped, remove the tape. ^ To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. ^ If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Heated Oxygen Sensor (HO2S) Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: ^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10406 path for foreign materials to enter the sensor and cause performance problems. ^ Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. ^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. ^ To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-B. SIR/SRS Wiring Repairs TOOLS REQUIRED J 38125-B Terminal Repair kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-B contains the following items: ^ Special sealed splices - in order to repair the SIR/SRS system wiring ^ A wire stripping tool ^ A special crimping toot ^ A heat torch The sealed splices have the following 2 critical features: ^ A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. ^ A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items: ^ A large sampling of common electrical terminals ^ The correct tools in order to attach the terminals to the wires ^ The correct tools in order to remove the terminals from the connectors Flat Wire Repairs NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Equivalents - Decimal And Metric Equivalents - Decimal and Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10407 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10408 Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10409 Conversion - English/Metric Conversion - English/Metric Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10410 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10411 Power Window Switch: Connector Views Window Master Switch - Driver C1 Window Switch - Front Passenger C1 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10412 Window Master Switch - Driver C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10413 Window Switch - Front Passenger C2 Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10423 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10424 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10425 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10431 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10432 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 10433 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair Sealing Strip Replacement - Front Door Upper Removal Procedure 1. Pull the molding (1) from the molding flange. 2. Remove the molding (1). Installation Procedure 1. Install the molding (1). 2. Push the molding (1) onto the flange. Start at the pre-formed corners. Work toward the straight flanges. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair Window Replacement - Lift Gate Tools Required * J 24402-A Glass Sealant (Cold Knife) Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Disconnect the washer hose from the liftgate. 2. Remove the back window wiper arm from the liftgate. Refer to Wiper Arm Replacement - Rear in Wipers/Washer Systems. 3. Open liftgate window. 4. Remove the liftgate window garnish molding. Refer to Garnish Molding Replacement Lift Gate (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) in Body Rear End. 5. Disconnect the electrical connector from the rear window defogger on the liftgate window. Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 6. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting 7. Using a sharp utility knife, make a preliminary cut around the perimeter of the quarter window. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10454 Important: Keep the cutting edge of the tool against the window. 8. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the window. 9. With the aid of an assistant, remove the liftgate window from the liftgate frame. Installation Procedure 1. Install a stationary window into the opening. Refer to Urethane Adhesive Installation of Stationary Windows (See: Service and Repair/Removal and Replacement/Urethane Adhesive Installation of Stationary Windows) . 2. Connect the electrical connector to the rear window defogger on the liftgate window. 3. Install the liftgate window garnish molding. Refer to Garnish Molding Replacement - Lift Gate (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) in Body Rear End. 4. Close liftgate window. 5. Install the back window wiper arm to the liftgate. Refer toWiper Arm Replacement - Rear in Wipers/Washer Systems. 6. Connect the washer hose to the liftgate. 7. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Quarter Window Glass Weatherstrip > Component Information > Service and Repair Quarter Window Glass Weatherstrip: Service and Repair Weatherstrip Replacement - Swing Out Window Removal Procedure 1. Open the swing out window. 2. Pull the weatherstrip from the pinch weld flange. 3. Grasp the weatherstrip at the lower corner and pull up and away from the pinch-weld. Installation Procedure 1. Install the weatherstrip to the pinch-weld flange. 2. Put the weatherstrip on the pinch-weld flange and push downward until fully seated. 3. Close the swing out window. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Replacement Door Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward. and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Front Side Door Water Deflector Replacement See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair 5. Install the inner panel upper bar. Refer to Inner Panel Bar Replacement - Front Door Upper () . 6. Remove the tape from the door and the window. 7. Check the window operation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10464 8. Install the trim panel. Refer to Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10465 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Window Regulator Replacement Tools Required M 39010 Heavy Duty Rivet Gun Removal Procedure 1. Remove the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 2. Remove the bolts that retain the inner panel upper bar. 3. Remove the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. Use a soft-faced scraper, if needed, in order to peel the water deflector away from the door. 4. Roll up the window. 5. Apply a cloth backed body tape from the window over the top of the door to the other side of the window in order to hold the window in position when the regulator is removed. 6. Disconnect the wiring harness from the power window regulator motor, if equipped. 7. Remove the window regulator rivet (2) heads by using a 6 mm (1/4 in) drill bit. 8. Remove the regulator (3) from the door: 1. Push the regulator into the door and slide the regulator forward and then rearward in order to remove the power window regulator arms from the sash and the regulator rail. 2. Fold the regulator arms together and remove it through the access hole. Installation Procedure Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement > Page 10466 1. Install the regulator (3) to the door: 1. Place the window regulator into the door through the access hole. 2. Place the window regulator arm rollers into the sash and the regulator rail. 3. Push the window regulator through the regulator door opening and align the holes in the regulator with the holes in the door. 2. Install the rivets to the window regulator (3) using the M 39010 . 3. Connect the wiring harness to the power window regulator, if equipped. 4. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 5. Install the inner panel upper bar with the bolts. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the tape from the door and the window. 7. Check the window operation. 8. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair Window Run Channel Replacement Removal Procedure 1. Roll the window up completely. 2. Remove the trim panel. Refer to Trim Panel Replacement Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . 3. Use a sharp bladed tool, if needed, in order to separate the water deflector at the perforations. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 4. Remove the door to window run channel bolt. 5. Pull the run channel away from the upper channel (which is part of the door) in order to remove the window run channel from the door. Installation Procedure 1. Slide the clip of the channel into the upper channel in order to install the window run channel to the door. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the door to window run channel bolt. Tighten the door to window run channel bolt to 9.5 N.m (84 lb in). 3. Install the water deflector. Refer to Water Deflector Replacement - Front Door See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair. 4. Install the trim panel. Refer to Trim Panel Replacement - Door (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair) . Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 10478 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 01-08-57-004 > Oct > 01 > Windshield - Water Dripping Into Interior From Top Windshield: Customer Interest Windshield - Water Dripping Into Interior From Top File In Section: 08 Body and Accessories Bulletin No.: 01-08-57-004 Date: October, 2001 TECHNICAL Subject: WaterLeak at Top of Windshield (Seal Pinhole) Models: 1999-2002 Chevrolet and GMC M/L-Van Models Condition Some customers may comment that there is water dripping from the top of the windshield. Cause Important: A large amount of water may be able to enter the vehicle through small holes in the body seam sealer The water may be entering from a pinhole in the body seam sealer at the upper "A" pillar. Refer to the illustration above. The water may also be entering from a pinhole in the body seam sealer at the "B" pillar and then runs forward to the windshield. Refer to the illustrations above. Correction 1. The affected surface must be clean, dry and free of dirt or contaminants. Clean the surface with one of the cleaners listed below, or equivalent. ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve BSS Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 01-08-57-004 > Oct > 01 > Windshield - Water Dripping Into Interior From Top > Page 10487 ^ Kent Acrosol 2. Fill the pinhole(s) with a clear seam sealer. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 10493 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-006 > Sep > 09 > Body - Stain/Film On Windshield Glass Perimeter > Page 10502 Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 09-08-48-002A > Mar > 09 > Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 01-08-57-004 > Oct > 01 > Windshield - Water Dripping Into Interior From Top Windshield: All Technical Service Bulletins Windshield - Water Dripping Into Interior From Top File In Section: 08 Body and Accessories Bulletin No.: 01-08-57-004 Date: October, 2001 TECHNICAL Subject: WaterLeak at Top of Windshield (Seal Pinhole) Models: 1999-2002 Chevrolet and GMC M/L-Van Models Condition Some customers may comment that there is water dripping from the top of the windshield. Cause Important: A large amount of water may be able to enter the vehicle through small holes in the body seam sealer The water may be entering from a pinhole in the body seam sealer at the upper "A" pillar. Refer to the illustration above. The water may also be entering from a pinhole in the body seam sealer at the "B" pillar and then runs forward to the windshield. Refer to the illustrations above. Correction 1. The affected surface must be clean, dry and free of dirt or contaminants. Clean the surface with one of the cleaners listed below, or equivalent. ^ 3M(R) General Purpose Adhesive Cleaner, P/N 08984 ^ Dominion Sure Seal, Sure Solve BSS Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 01-08-57-004 > Oct > 01 > Windshield - Water Dripping Into Interior From Top > Page 10511 ^ Kent Acrosol 2. Fill the pinhole(s) with a clear seam sealer. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 06-08-43-003C > Feb > 11 > Glass/Body - Windshield Wiper Performance > Page 10517 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10522 Windshield: Service and Repair Windshield Replacement Tools Required * J 24402-A Glass Sealant (Cold Knife) Remover * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 2. Remove the antenna if necessary. Refer to Fixed Antenna Replacement in Entertainment. 3. Open the hood. 4. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair) in Body Front End. 5. Remove the inside rearview mirror. Refer to Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Rearview Mirror Replacement) . Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury. 6. Cover to protect the following parts from broken glass: 1. Upper dash pad 2. Defroster outlets and A/C outlets 3. Seats and carpeting 7. Remove the door sealing weatherstrip from the upper pinchweld flange. Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. 8. Remove the 2 screws that retain the windshield frame filler panels. 9. Remove the frame filler panels. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10523 Important: The windshield reveal molding fills the cavities between the body and windshield and can not be reused if stretched or damaged. 10. The windshield reveal molding is a one piece molding. Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury. 11. Grasp the lower corner of the windshield reveal molding by hand and slowly pull the reveal molding away from the windshield. If the windshield reveal molding will not release, use a utility knife in order to cut around the windshield in order to remove the windshield reveal molding. 12. Remove the windshield reveal molding. 13. Remove the lower windshield supports (1) from the cowl panel, if equipped. Important: Keep the cutting edge of the tool against the quarter window. 14. This will allow the urethane adhesive to be separated from the quarter window. * Leave a base of urethane on the pinchweld flange. * The only suitable lubrication is clear water. * Use J 24402-A , J 39032 or equivalent in order to remove the quarter window. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10524 15. Remove the windshield (1) from the vehicle with the aid of an assistant (2). Installation Procedure 1. Install the quarter window into the opening. Refer to Urethane Adhesive Installation of Stationary Windows (See: Windows/Service and Repair/Removal and Replacement/Urethane Adhesive Installation of Stationary Windows) . Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the windshield side reveal molding screws. Tighten the windshield side reveal screws to 2 N.m (18 lb in). 3. Install the windshield frame filler panel with 2 screws. Tighten the windshield frame filler panel screws to 2 N.m (18 lb in). 4. Install the door sealing weatherstrip to the upper pinchweld flange. 5. Install the inside rearview mirror. Refer to Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Rearview Mirror Replacement) . 6. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair) in Body Front End. 7. Close the hood. 8. Install the antenna, if necessary. Refer to Fixed Antenna Replacement in Entertainment. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wipers/Washer Systems. 9. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10530 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Rear Window Wiper Washer Switch Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Remove the washer hose from the rear washer pump to the rear washer check valve. 3. Remove the rear washer check valve. 4. Remove the washer hose from the front washer pump to the front washer check valve. 5. Remove the front washer check valve. 6. Remove the front washer hose and strap. 7. Remove the washer hose connector from the plenum clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 10541 8. Remove the RH washer nozzle hose and hose clip. 9. Remove the LH washer nozzle hose from the 2 plenum clips. 10. Remove the LH washer nozzle hose and hose clip. INSTALLATION PROCEDURE 1. Install the LH washer nozzle hose with the hose clip. 2. Install the LH washer nozzle hose in the 2 plenum clips. 3. Install the RH washer nozzle hose with the hose clip. 4. Install the washer hose connector in the plenum clip. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 10542 5. Install the front washer hose and strap. 6. Install the front washer check valve. 7. Install the washer hose from the front washer pump to the front washer check valve. 8. Install the rear washer check valve. 9. Install the washer hose from the rear washer pump to the rear washer check valve. 10. Install the washer solvent container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10546 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10547 Windshield Washer Pump: Diagrams Rear Window Washer Fluid Pump Windshield Washer Fluid Pump Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10548 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the washer solvent container. 2. Disconnect the washer hose(s). 3. Remove the washer pump(s) from the washer solvent container. INSTALLATION PROCEDURE 1. Install the washer pump(s) in the washer solvent container. 2. Connect the washer hose(s). 3. Install the washer solvent container. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement - Rear Wiper Arm: Service and Repair Wiper Arm Blade Replacement - Rear REMOVAL PROCEDURE 1. Insert a narrow-bladed screwdriver into the slot over the wiper blade retainer spring. 2. Pivot the screwdriver so that the blade tip presses downward on the retainer spring and releases the wiper blade from the pin of the wiper arm. 3. Remove the wiper blade from the wiper arm. INSTALLATION PROCEDURE 1. Install the wiper blade on the wiper arm pin. 2. Snap the wiper blade into place. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement - Rear > Page 10556 Wiper Arm: Service and Repair Wiper Arm Replacement REMOVAL PROCEDURE 1. Remove the washer hose from the wiper arm. IMPORTANT: Before removing one or both of the arm and blade assemblies, use a suitable marker on the windshield to indicate the proper part position and to aid in reinstallation. 2. Lift the wiper arm assembly from the windshield, then pull the retaining latch. 3. Remove the arm assembly from the transmission drive shaft. INSTALLATION PROCEDURE 1. Position the wiper arm assembly on the drive shaft and press in the retaining latch so that the wiper blade aligns with the mark made before the removal. 2. Install the washer hose. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Blade Replacement - Rear > Page 10557 Wiper Arm: Service and Repair Wiper Arm Replacement - Rear REMOVAL PROCEDURE IMPORTANT: Mark the position of the wiper blade on the liftgate with a suitable marker or a piece of masking tape. 1. Pull the washer hose through the liftgate grommet. 2. Disconnect the washer hose from the washer harness connector. 3. Lift the wiper arm off the liftgate. 4. Push out the wiper arm retaining clip with a small screwdriver. 5. Remove the wiper arm from the wiper motor drive shaft. INSTALLATION PROCEDURE 1. Position the wiper arm onto the wiper motor drive shaft so that the tip of the blade aligns with the mark made at removal. 2. Install the wiper arm onto the drive shaft. 3. Press in the retaining clip. 4. Connect the washer hose onto the washer harness connector. 5. Insert the hose into the liftgate grommet. 6. Operate the rear wiper and inspect for proper operation. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 10562 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Element Replacement Wiper Blade: Service and Repair Wiper Blade Element Replacement REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Squeeze the wiper blade element tabs together. 3. Pull the wiper blade element out through the wiper blade claws. INSTALLATION PROCEDURE 1. Slide the wiper blade element through the bottom claw of the wiper blade. 2. Guide the wiper blade element through the wiper blade claws until both of the locking tabs engage the bottom claw set. 3. Install the wiper blade on the wiper arm. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Element Replacement > Page 10565 Wiper Blade: Service and Repair Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade Element Replacement > Page 10566 Wiper Blade: Service and Repair Blade Element Replacement - Rear REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Squeeze the wiper blade element tabs together. 3. Pull the wiper blade element out through the wiper blade claws. INSTALLATION PROCEDURE 1. Slide the wiper blade element through the bottom claw of the wiper blade. 2. Guide the wiper blade element through the wiper blade claws until both of the locking tabs engage the bottom claw set. 3. Install the wiper blade on the wiper arm. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10570 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED ^ J 39232 Wiper Transmission Separator ^ J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Disconnect the transmission drive link from the wiper motor crank arm with the J 39232. 4. Remove the transmission to cowl nuts. 5. Remove the wiper transmission from the vehicle through the access openings in the top of the cowl. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 10574 1. Install the wiper transmission on the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the transmission to cowl nuts. Tighten Tighten the transmission nuts to 14 N.m (10 lb ft). IMPORTANT: Assemble the wiper transmission to the crank arm past the second detent so that the seal is compressed to a maximum height of 25.5 mm (1.0 in). Lubricate the inside of the socket with a lithium-based grease (GM P/N 1050109, 1052196 or equivalent). 3. Connect the transmission drive link to the wiper motor crank arm using the J 39529. 4. Install the air inlet grille panel. 5. Install the wiper arms. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10578 Locations View Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 10579 Wiper Motor: Diagrams Rear Window Wiper Motor Windshield Wiper Motor And Module Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement Wiper Motor: Service and Repair Wiper Motor Replacement TOOLS REQUIRED ^ J 39232 Wiper Transmission Separator ^ J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the wiper arms. 2. Remove the air inlet grille panel. 3. Disconnect the transmission drive link from the wiper motor crank arm using the J 39232. 4. Remove the wiper motor electrical connector. 5. Remove the three bolts. 6. Remove the wiper motor from the vehicle. INSTALLATION PROCEDURE Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 10582 1. Install the wiper motor on the vehicle. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the 3 bolts. Tighten Tighten the 3 bolts to 7.0 N.m (62 lb in). 3. Connect the wiper motor electrical connector. IMPORTANT: Assemble the wiper transmission to the crank arm past the second detent so that the seal is compressed to a maximum height of 25.5 mm (1.0 in). Lubricate the inside of the socket with a lithium-based grease (GM P/N 1050109, 1052196 or equivalent). 4. Connect the transmission drive link to the crank arm using the J 39529. 5. Install the air inlet grille panel. 6. Install the wiper arms. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 10583 Wiper Motor: Service and Repair Wiper Motor Module Replacement REMOVAL PROCEDURE 1. Remove the wiper motor electrical connector. 2. Remove the cover screws. 3. Remove the cover. 4. Remove the circuit board and terminal module by lifting up on the terminal. INSTALLATION PROCEDURE 1. Install the circuit board and terminal module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cover and 3 screws. Tighten Tighten the screws to 2.6 N.m (23 lb in). 3. Install the wiper motor electrical connector. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Replacement > Page 10584 Wiper Motor: Service and Repair Wiper Motor Replacement - Lift Gate REMOVAL PROCEDURE 1. Remove the liftgate garnish molding. 2. Disconnect the wiper motor electrical connector. 3. Remove the wiper arm from the wiper motor. 4. Remove the nut, the spacer, and the seal. 5. Remove the 2 bolts and the wiper motor from the liftgate. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the wiper motor to the liftgate with the 2 bolts. Tighten Tighten the bolts to 7.0 N.m (62 lb in). 2. Install the seal, the spacer, and the nut. Tighten Tighten the nut to 6.0 N.m (53 lb in). 3. Install the wiper arm and blade. 4. Connect the wiper motor electrical connector. 5. Install the liftgate garnish molding. Chevrolet Astro Van 2wd Workshop Manual (V6-4.3L VIN X (2002)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Rear Window Wiper Washer Switch